Alex's Project

[Alexhoc]

Right, seeing as I finally started something properly, I may as well put it down here!

I bought a 1996 100 LWB SHR 2.5Di a few months back, with a view to turn it into a camper (mostly for overnight stays, not 2 week long holidays), as well as a bike carrier for track days. Anyway, here is what I bought back then:



I did get the wheel trims for it though, I really didn't like the looks of the standard wheels...

Soon after I got white indicators to update the looks a bit


And this weekend fitted some decent wheels to it
Before

After





Some mentionned clearance issues with the SLD:

I guess they were right! It's not too bad though, the door just rubs on the tyre and still opens enough


Plans for the future are:

V6 conversion, although I am mighty tempted by a v8...
Windows in all the doors
Camperish conversion in the back, must sleep 3, and leave me enough room to load the motorbike. I will do something not far from Alan's van, at least the general idea.
Will be resprayed black.
I need some spotlights for the front, not sure how many I'll want yet, I'll see how it goes.

That is it for now, loads to do yet, bodywork needs attention, I need to make myself some wider arches for the rear, etc.

On a side note, my van is fitted with a full bulkhead and security locks on the rear doors. I can't see the point of having them as I will sell the bulkhead, and as I want to get windows anyway, would it be worth buying doors with windows and selling mine with the locks? If you reckon somebody might want them (fair bit of rust on the bottoms), I'll put an advert up when the time comes...

[MinorMatt]

Hi Alex

Looks promising, im going to convert my van soon (im thinking about a pop top roof). With regards to the bulkhead unless you are thinking you are going to want to jump in to the front from the back can't you just unbolt the "window" section? It also makes privacy in the rear easier!

Im thinking of modifying the bulkhead I have to have an opening door and window(s) in it!

[Alexhoc]

Hi Matt,

I won't jump in the front from the back as such, but the front seats will form a child sized bed once folded forwards. The bench seat on my Peugeot Boxer would do that so I'm going to try to get one of these to fit... I will fit some sort of curtains all around the cabin and also to partition the rear bed...

On that subject, I will also try to make the bench seat back adjustable, so it can be comfy for long journeys... has anyone ever attempted that?

[Luke]

love the stance with the wellers on you dont see many lwb's with them but they do suit it

look forward to the updates

[AlanN]

The 8 spokes are looking totally PHAT maybe a narrower tyre or pack out the runner a little then carefully seal off with some silver sillicone sealer...

[Alexhoc]

I don't think I'll bother Alan, the door opens wide enough as it's the LWB, I'll see what happens when the wide arches are on... I just wanna use it as a camper/dayvan, I won't load pallets through the side so I might even make it stop just short of the wheel...

[hdegroot]

nice

[Ford Sprung Van Tastik!!]

love the stance with the wellers on you dont see many lwb's with them but they do suit it

look forward to the updates

Pity we can't find them for the 150 / 190 6 stud wheels

[Alexhoc]

Not so much an update but more of a refinement, I have now settled on a 24v (Cosworth with a bit of luck). I have arranged to buy a flywheel and adapter plate to fit it to my box. Would the engine mounts be easy enough to make? how about the exhaust, I read somewhere the manifolds are a problem?

Are there any other specialist parts I forgot about?

I am quite handy with a welder, even if I do say so myself...

[Guy88]

Not so much an update but more of a refinement, I have now settled on a 24v (Cosworth with a bit of luck). I have arranged to buy a flywheel and adapter plate to fit it to my box. Would the engine mounts be easy enough to make? how about the exhaust, I read somewhere the manifolds are a problem?

Are there any other specialist parts I forgot about?

I am quite handy with a welder, even if I do say so myself...

Engine mounts can be done, exhaust manifolds are a custom job

If the mountings are the same you can mod a set of MK3 engine mounts extremley easily and then use the std granny items to bolt it to the engine

[OxtonyxO]

engine mounts are a problem they are about 2" too low on the mk5 so you either need to lift them up or make new mounts.
the exhausts foul the adapter plate so you need to make some manifolds.
also the bulkhead needs a "tap" to push it back
and it may be easier to fit a second batt as the granny loom is on the wrong side
one last thing is the fuel , either find a DOHC tranny fuel tank (with the efi pump inside), or fit a lift pump and swirl pot.
ie one lift pump to supply the swirl pot, then swirl pot to supply the efi pump (efi pump won't suck)
i used a red top lift pump with swirl pot and sierra cossie efi pump

hope this helps

[Guy88]

engine mounts are a problem they are about 2" too low on the mk5 so you either need to lift them up or make new mounts.


hope this helps

MK3 ones cure this

[OxtonyxO]

how can you change to mk3 ?

swirl pot

engine mount (temp )

exhaust manifolds

adapter plate (note piece welded to the top)

[Guy88]

how can you change to mk3 ?

You only use the bit that bolts to the chassis. if its not a direct swap it would be an easy mod.

Where they sit at 45* with the slot in cut down the edge, bend the slotted bit up so its horizontal then plate each side and a weld and your done.

I made the stupid mistake of leaving mine on the van when i scrapped it

[OxtonyxO]

are the mounts easy to remove/ whats involved ?