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Mk7 Race van build

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Mk7 Race van build

Postby Harvy » Mon Oct 07, 2024 7:06 pm

Hi all,

I recently bought a MK7 LWB L4 H3 2.4 115 transit and joined this forum to learn things and share what I’ll be doing to it. Firstly this is a budget purchase and a budget build so don’t expect anything super high quality! :D

The Plan:

The end goal is to have a vehicle that I can store and transport my sons go kart in the back of, and my family in the front of. For test days we just take the van and have a day area in the sliding door where we can eat our sandwiches and go over data etc. My plan is to have a bulkhead behind the sliding door to separate this area from the ‘garage’ in the back. I would like the day area to consist of 3 forward facing seats against the bulkhead, a permanently fixed table and 2 rear facing seats back to back with the drivers seat. The idea being that on the really long journeys when we have the big caravan on the back my wife and the children can sit at the table and do colouring or jigsaws etc to keep themselves entertained whilst I drive. The current method of taking both cars for the local tracks with me towing the caravan and my wife towing the trailer is unsustainable, and the longer distance journeys require me to empty the whole trailer into the caravan which is plain ridiculous!

The Search:

I had initially decided to get a twin wheel transit minibus and did a lot of research into driving a minibus with out a D1 or PCV and found out that it is possible as long as the seating capacity doesn’t exceed 16 passenger seats and it is for Social Domestic and Pleasure or other charitable reasons. I found a suitable van in Dumfries and went to view it, liked it, and put in offer in pending me getting insurance. Cue two days of being on the phone/internet to loads of different specialist and generic insurance companies to no avail. It turns out that apparently the bottom has fallen out of the SDP minibus insurance market in about June this year. Even Adrian flux were unable to offer any insurance with all 16 seats in as they can no longer offer cover for SDP minibuses. They did say that if I reduced the seating capacity to 8 passengers (as was my intention) and register the vehicle like that then they could offer me insurance starting at £2500 per year! :shock: So that put paid to that idea.

I started looking into getting a van and putting seats in the back instead. I was pleasantly surprised at how unregulated it appears to be to add seats to a van. To be honest this is one of the most blasé webpages on a .gov website I think I have seen!

https://www.gov.uk/government/publicati ... n-the-rear

Tl;dr Do what you want maybe think about bolting the seats down and maybe have seats belts, we don’t really care!

That’s how I have ended up with this big white van! It’s old and needs some attention but it was a good price and not too far from me. 196,000 miles but it seems to run pretty well considering.


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I have various things I would like to do to it, a shopping list of parts some have already arrived and more are in the post. I’ll keep you updated on how I get on.
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Re: Mk7 Race van build

Postby Harvy » Mon Oct 07, 2024 7:41 pm

The first job is the propshaft bearing. On the drive back I heard an odd low pitch vibration that’s not to different to when you have the back windows open in a car but the front ones shut, only at a higher frequency. Initially I put it down to being a bare van and some odd wind vibration. Upon inspection underneath I came across this.

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The front bearing, I’ll see if I can upload a video later. (Not sure how yet)

I phoned my local motorfactors who had one in stock, so when I finished work today I went to collect it then did this.

IMG_2190.jpeg

I love the face that it can be done with no jacks, axle stands, ramps or blocks of wood. There is plenty of space under the van!

Having got it out I realised that the other bearing carrier had been badly damaged, so I phoned the motorfactors to order another bearing to replace the rear one whilst I have it all out.

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I took the shaft apart and fitted the one bearing I have, the other one will have to wait for a couple of days until I get a chance to go and play with the van again!

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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Mon Oct 07, 2024 7:44 pm

One more small addition that arrived in the post today,

IMG_2195.jpeg


The van was missing a fuel cap so eBay came to the rescue.
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
Transit Aficionado
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Thu Oct 10, 2024 9:54 pm

I’ve had a chance to do a little more today.

I’ve added the second new propshaft bearing and reassembled the propshaft.
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I refitted it to the van with liberal amounts of loctite as I don’t want it coming off! Whilst fitting it I saw this behind the fuel tank. It looks like some kind of heat sink but for what?

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A few days ago I took the liberty of holding and wiggling the offside bump stop and it took exception to that! The old perished rubber gave up and fell out of the steel dish. So I got a new one from the ford shop on eBay…

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And fitted it. I wouldn’t like to do that with any weight in the back as the ratchet and extension only just for over the axle.

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It rained on and off while I was doing this but I stayed nice and dry under the van! :lol:
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Wed Oct 16, 2024 11:13 am

A very small job I did the other day was to unclog the windscreen washers. Every time I used a needle to clean out the jets they would almost immediately block up again. So I had to take the under bonnet lining off (breaking all but one of the trim clips in the process :evil: :roll: ) to access the rubber feed hoses. I blasted them out with compressed air and loads of grime came out of them, refitted and they work perfectly now. I had to wait for some new trim clips to arrive from eBay before refitting the lining.

IMG_2216.jpeg
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sun Oct 27, 2024 8:31 am

Morning all, I have been doing things recently I’ve just not had time to write a proper post. One task was to remove all the lining and flooring so I can see just how bad the metal work is and do my best to clear some of the rubbish out.

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I forgot to take a photo before I started, but the removal of the flooring was hard as all the screws that were holding the floor down had heads that were so rusty they wouldn’t undo. So out came the pry bar.

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All gone. I used my garage hoover to clear the worst out of the back. I must have sucked up about 2kg of screws from all the crevasses near the inner arches and lots of carpet fluff as the van used to be used for carpets going by some faded marks on the outside.

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I did find some additional ventilation! :shock: The front of both inner wheel arches are no longer attached to the floor.

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I have managed to find the inner arches on eBay for about £69 each.

https://www.ebay.co.uk/itm/144952594706 ... p_homepage

I’ve yet to find a floor panel. I don’t intend to take the whole panel out, just cut it back to good clean metal and replace it with bits cut out of a new floor panel. Although I could just plate it with steel sheet? Any advice on this would be gratefully received! :D
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Wed Aug 20, 2025 9:29 am

I’ve had lots of mechanical problems with the van but I’m going to try and keep this thread for things related more to the race conversion etc.

Back in November I bought 5 seats out of a Vauxhall I think. They were fairly local, £125 for all of them and came with integral seatbelts. This final point made fitting them a lot easier as all I needed to do was bolt them down and not have to find seperate seatbelt anchor points. I only needed 3 of the seats so sold the other 2 for £50 :mrgreen:.

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I went to my local steel stockholder and picked up some chunky box section steel, cut it to size, drilled holes in it to bolt it through the floor and then drilled some more holes and welded some nuts inside the box section to bolt the seats to it. I used this method because bolting the seats straight to the floor was not feasible due to where the holes would need to be drilled. When bolting the box section to the floor I drilled though the floor and cut some ‘washers’ from some 5mm steel plate to spread the load.

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Next I bolted the seats to the box section using some of the original spaces supplied with the seats to angle them backwards so they are more comfortable over long distances.

IMG_2553.jpeg


This is the end result. The distance between the front seats and the ones I fitted is deliberately large as I intend to fit some sort of table between them and make the front seats spin so it can be used as a day van. Somewhere we can sit out of the rain to eat our sandwiches and go over performance data.

IMG_2554.jpeg


My intention is to fit a bulk head behind the second row of seats so as to separate the passengers from the garage area of the van. I positioned the second row of seats in such a way that even after I’ve added a bulk head I will still be able to get 1200 x 2400 sheets in the garage part of the van without them having to go diagonally. Meaning I can still use it as a van if I need to move large things. :mrgreen:
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sun Aug 24, 2025 8:15 am

To stop us getting wet inside while driving in the rain I decided to cut out the metalwork around the non factors ventilation holes :shock:

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I had to drill all the spot welds out of this and remove it….

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So I could drill all the spot welds out of the arch and remove it. Can anyone recommend some good drill bits for steel? I wear through my cheap ones quite fast.

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Then I had to do it all to the other side too.

IMG_3315.jpeg
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sun Aug 24, 2025 8:36 am

Next it was time to start rebuilding it. I bought the arches from eBay for £69 ( :twisted: ) each. Went to my local steel stockholder and bought a 1200mm x 2400mm sheet of 1.2mm for £20. He even cut it into 3 manageable pieces with a huge set of shears! :o He also told me he has a panel folder so can put folds in the steel if I wanted too. Only 5 mins away too so really useful.

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This is one side done and a polyurethane sealer bead along all the welds and joins.

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This stuff is so good and relatively inexpensive. I think £15 for 3 on Amazon, I can highly recommend.

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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sun Aug 24, 2025 8:46 am

I had to do a half shaft seal as it was leaking.

IMG_3344.jpeg


Fortunately I didn’t have to undo this and take the back seal out. It looks like somebody has been struggling with it in the past :shock: .

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After cleaning up the surfaces and refitting the seal, no leaks! I did have to top up the diff as well.
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Mon Aug 25, 2025 9:07 am

I took the van for MOT knowing it would fail but I wanted a professional opinion on what welding needed doing. The chap and the commercial garage was very helpful and took me underneath in on the ramp and showed me in detail what was required. There were a couple of patches on the chassis that needed cleaning up, cutting out and plating so I did so.

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My welds are not pretty :oops: but I have to learn somewhere!

By adding the second row of seats I made this little bit of rust within the prescribed area for a seatbelt mounting point. Talk about making work for yourself! :lol:

IMG_3396.jpeg


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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Mon Aug 25, 2025 9:15 am

There was a lot of rust that needed cutting out behind the rear wheels. So I’m glad I bought large sheets of steel.

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Shines new brake line for the NSF as well as a drop link and full set of pads for the front.

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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
Transit Aficionado
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Mon Aug 25, 2025 9:24 am

Next I had the drivers door sill and step. I started poking it hard and all this came away! :shock:

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The step had already been repaired once but not particularly well.

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So it all had to go…

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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
Transit Aficionado
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Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sat Aug 30, 2025 9:36 am

Then it was time to rebuild it. I bought a panel kit from eBay for not very much money.

https://ebay.us/m/yQsU9r

I spent some time working out the order that I would have to weld the panels I so as to make sure I could get to all the seams to weld them. After some cutting of the new panels I started tacking them in.

IMG_3478.jpeg


Behind the step on the inner sill the new panels I kit didn’t extend far enough, so I had to make my own panel.

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After a lot of welding (I know it’s not pretty but there is penetration so it strong enough, this van is the only welding I have ever done!), and a little bit of swearing, it looked a lot better.

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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
Transit Aficionado
Transit Aficionado
 
Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

Re: Mk7 Race van build

Postby Harvy » Sat Aug 30, 2025 9:41 am

Following on from the last post….

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The silver paint is a galvanising base coat

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Followed by some rattle can frozen white! :mrgreen:

IMG_3495.jpeg
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2010 T350 LWB H3 RWD 2.4 115 Full poverty spec! :D
Harvy
Transit Aficionado
Transit Aficionado
 
Posts: 254
Joined: Sun Oct 06, 2024 9:02 am
Location: South Yorkshire

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