few jobs on my mk2 swb, turbo di and pas conversion etc.

[oldskooler]

heres a few pics of recent progress getting the engine ready for the transplant.


as i got it.



first i took off the turbo manifold as there was a bad blow due to the missing/broken studs.





after gettin the broken studs out i cleaned up the turbo/manifold assembly and where it goes.



i got a new gasket for reassembly.



i also done the tappet clearances when i was at it.

all back together. i also removed the egr assembly and made up blanking plates for the manifolds.







few bits left to do, fit new timing belt and water pump to be sure and im nearly ready to go hopefully!!

[oldskooler]

well i got stuck into it for the xmas hols as planned. i had some setbacks but im almost back on track again!


started stripping the front.



pinto and box removed.




i decided to move the battery tray over to the drivers side as should be in a diesel. this also means i can use factory mk5 leads and alternator connections etc.


started removing tray.









next i removed the support.



i discovered that not only can the tray be swapped from side to side but also the support panel is symetrical and can be used on either side!! good old ford engineering!!!







next i gave the bay a good clean with some panel wipe and it came up fairly well.



next i found some nasties round the bonnet hinge mountings.

they looked to have been covered up with filler previously and were beginning to show again.



after some cleaning this is what i found both sides.





the renforcement panels behind the inner wings looked like this and werent hard to remove!! they in turn rotted the inner wings around the hinges (common in theese vans it seems)



luckily the holes were still intact after i cut back to get good steel so i didnt have to worry bout position of holes for the hinges. i made a couple of sections to flush fit and weld in place.









next i made two renforcement plates to replace the rotten ones.



after giving the plates and inner wings a coat of weld through primer where they meet i clamped them in position and spot welded them in place as they were originally.





all done, just needs a light skim of filler to even off before painting. also have to seal up the plates under the wings and stonechip them.





i wasnt expecting this much work but im glad i got it sorted properly when i got the chance with the engine out.
just to paint the inner wings now and i can get back to the transplant!!

[madmark]

wow mate what a great job you done there ,keep the photo,s comeing love the thread!

[Luke]

thats how it should be done

[jerry2]

That's a lovely clean van there m8. Had to do the same repairs on my mk2 hinges as well.

[oldskooler]

todays progress,

got a skim of filler on the repairs and got them rubbed down.



then a touch of primer and i flatted the areas to be painted.





my mate called this eve and done the painting for me.







looks better now!!







i got my hands on a pair of mk4 mounts last week so i dont have to change the mk2 chassis brackets. i gave them a clean and paint and hopefully ill be bolting them up tomorrow!!

[oldskooler]

bit more done over the last couple of days,

got the lump sitting in.



i cut out a disc with a 4 inch holesaw for the new gearstick hole, will worry bout dressing this later.



after some head scratching i decided to make a new crossmember for the mt75 from box section rather than bodging the mk2 and mk5 member together.






i started doing some plumbing, starting with the fuel lines, im using the complete mk5 setup.



i recently hauled this girl out of this hedge, shes an original di and so far has been usefull, ill be using the tank sender with the return and various other bits.







i also intend to use the original mk2 di engine mounted header tank, had to mod the bracket for the new type stat housing. should look the part!




before i went any further back with the fuel lines i thought id better tackle the exhaust system first so id be able to keep the pipes etc away from the heat. i had a fairly fresh middle and back section from the crashed swb mk5 donor van im using and i got a new standard mk5 front pipe on the cheap!! this job took a good while cutting and shutting to get it sitting right but im happy enough. again i used the hanger brackets from the mk5 to match the system, i may indeed weld a couple of bits on to use a couple of the mk2 hangers thats left on the body.

front pipe and middle section hung. luckily the first few inches of the turbo front pipe came with the engine.



back section on.









another job done, still plenty to do!!!

[madmark]

wow love it ,well done mate this should tow like a train when she is up and running

[Luke]

quality

have i allready said the mk3/4/5 floor piece will fit strait into your mk2 - so you'll have the propper MT75 gear stick gator make areal neat job and a van like this deserves it

this bit fit's like a glove

[oldskooler]

quality

have i allready said the mk3/4/5 floor piece will fit strait into your mk2 - so you'll have the propper MT75 gear stick gator make areal neat job and a van like this deserves it

this bit fit's like a glove

cheers luke, ya, im thinkin strongly bout it as i have that complete section in the donor van. just wondering how will the mat fit over the raised section. im toying with another idea.....maybe weld and smooth off a disc into the original steel trim that screws into the floor and make a tower to go round the new stick and take a gaitor (will be close, plate may need slight trimming) i could them use the original plate to seal the old hole and just cut the mat to fit round the new tower. the floor mat is mint and id like to keep it original looking. gonna leave this job till last as im still undecided and want to give it some time. have you grafted said panel into your 24v??

another question, thinking ahead......am i right in thinking that the feed to the starter solenoid on the later vans are relayed?? in other words is there a larger draw and would i need to relay the starter feed from the key or i wonder is the mk2 switch man enough. maybe im wrong, just seems to be a slight delay when you turn the key to start the mk5,s?

[Luke]

yeah the mk2 origanal mat wont fit with it - thats a down side but you cant keep it origanal with the stick in the 'wrong' place anyway

also the mk3/4/5 mat fits over the middle bit but isnt too good a fit at the edges - i was gonna have a custom 3 piece matt made up - i think transitgeoff had one in his mk1 pickup that looked spot on

and yeah i grafted that exact bit in the pic into my 24v'er

[oldskooler]

the 3 piece mat sounds like a good plan, will play it by ear and see. next priority is get power and fuel to her and see if she fires up!!!

[BROWNYS V6]

in reply to your other question there is a relay on the starter circuit as i fitted one to my mk3 when it had a di in it.on your mk5 doner its located on the inner wing on the drivers side mounted on the black plate that drops down off the side of the battery tray
nice conversion by the way,looking good

[oldskooler]

in reply to your other question there is a relay on the starter circuit as i fitted one to my mk3 when it had a di in it.on your mk5 doner its located on the inner wing on the drivers side mounted on the black plate that drops down off the side of the battery tray
nice conversion by the way,looking good

thats great info, will graft in the mk5 one, cheers mate.

[AndyG]

Nice work
Just to say, on my MK5s, the starter relay is behind the glove box