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Vanzilla! An 05 Connect LWB boating battle bus!

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Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Fri May 09, 2014 7:01 pm

As promised I thought I would start a progress log for my van, an 05 Transit Connect LWB 90ps L spec. Vanzilla is her name as she was a bit of a monster when we first got her...

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166000 miles on the clock with what appears to be good service history. Well, maybe they were changing the oil, but not doing much about the rest! Think she was an Hgv escort vehicle as she has the relay for beacons and the wiring in place. Also there was still a bit of the vinyl left in place in the colors of a local haulage firm.

Anyway, the initial teething troubles are mainly dealt with. She needed 4 new injectors courtesy of DieselBoy1978, a new cat down section, the egr blank has cured a stutter at 2000rpm (thanks to Paul for that one) and some smaller electrical bits and pieces are all out of the way and the van is being driven daily. Most service fluids are up to date, with ps, brakes and coolant still to do.

A few more bits and pieces still to take care of on the mechanical side but on the less urgent pile are:

- new clutch to cure the gearbox thrash
- new rear drums and shoes to cure uneven rear braking
- troubleshoot intermittent abs light - suspected rear sensor
- new exhaust middle and final section
- 2 new front foglights
- new vacuum pump or vacuum pump seal to cure slight oil leak
- re seat sump to cure slight oil leak
- new timing belt and water pump when opened up
- deal with rust on underside and seal

So a good list to be getting on with. I have to admit I like the van. Running costs are pretty decent and parts don't break the bank. If I had a list like that to contend with on something a bit fancier I don't think I would bother!

So on to the main purpose of this van. I love my sailing. Specifically, me and my partner sail an RS400. It takes us all over the uk to events, and last year we made it to Ireland and France! Great fun, but the vehicle we were using was not as practical as it could have been, and didn't do too well on fuel... Grand cherokee 4.7l v8 ho overland ;-)

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So the plan is to get the van reliable and pleasant to drive with a converted and lined out rear, and use it to hit the circuit hard this year and beyond! We considered a larger van, but in the end came to the conclusion that all you really need at events is a place to crash as sailing clubs have showers and food and so on... And this was reflected in our experience of the circuit last year (in our tent!)

So step one was for a tow bar... Which owing to a build up of rust in the chassis threads was a bit of a pain. Just had to keep working the bolt in and out and cleaning it. I finished fitting it last night and have yet to try it, but it looks good!

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Next up will be tacking my list above and doing the insulation etc. looking forward to the build!
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby g-man » Fri May 09, 2014 7:05 pm

:D should have just knocked the gut outa the cat.....still pass the mot :wink: ...........keep the pics coming 8)
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Mon May 12, 2014 1:45 pm

Fitted new number plates fore and aft, and got one for the new lighting board. Plain with Euro GB all round for continental towing. Also realising that a few events are fast creeping up on us I got some stuff in to start the lining out of the rear. 3 rolls of Flash band, 1 bale of recycled polyester insulation, 3 rolls of foil backed bubble wrap... Cant wait to get started! :-)
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby MinorMatt » Mon May 12, 2014 3:57 pm

g-man wrote::D should have just knocked the gut outa the cat.....still pass the mot :wink: ...........keep the pics coming 8)


As of March this year it shouldn't pass anymore with the guts of a cat/dpf knocked out
Lucas Laser 2000/IDS
95 Pre Production DRW TD Highcube
95 Hallmark
96 150 100PS LWB Hi-Top
96 Autosleeper Duetto
06 Mk7 (scrap)
09 140PS T330S 2.2

Gaffa tape is like the force, it has a light side, a dark side, and it holds the universe together
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Mon May 12, 2014 8:46 pm

Lol! Glad I kept it in! To be fair, having dropped 100 notes on a cat I didn't feel like smashing it up. If the old one hadn't split at the flexi section I might have been tempted! :-). Annoying though that you have to change the cat just for a broken flexi...
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Sat May 17, 2014 12:23 pm

So work continues on the list, got the rear brakes done. New drums and shoes etc. looking good, but the nuts are letting it down. Any recommendations on a new set of chrome ones?

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mishnish
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby MinorMatt » Sat May 17, 2014 4:13 pm

They are the same as car ones...

get ones for a focus/mondeo etc and they come with chrome "covers"
Lucas Laser 2000/IDS
95 Pre Production DRW TD Highcube
95 Hallmark
96 150 100PS LWB Hi-Top
96 Autosleeper Duetto
06 Mk7 (scrap)
09 140PS T330S 2.2

Gaffa tape is like the force, it has a light side, a dark side, and it holds the universe together
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Sat May 17, 2014 6:49 pm

Got these coming now... Thought I'd go the all black route!

http://www.ebay.co.uk/itm/181322435956
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Sat May 17, 2014 6:57 pm

Balls! Just discovered all my tyres are 91 load rated...
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby g-man » Sun May 18, 2014 10:56 am

MinorMatt wrote:
g-man wrote::D should have just knocked the gut outa the cat.....still pass the mot :wink: ...........keep the pics coming 8)


As of March this year it shouldn't pass anymore with the guts of a cat/dpf knocked out


probably so with dpf because of lower CO2,but he has'nt got one.....but if its passed upto now with guts knocked out of cat it will be ok.......but not apparently with cat missing
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Tue May 27, 2014 11:08 pm

Been a busy boy lately, got a load done to the van though! Will post some pictures up tomorrow as dark just now and really wanted to test drive all the latest changes!

First up new discs, pads, drums and shoes all round. The condition of the existing brake hardware was actually not that bad, but it was evident that the two rear drums had been replaced independently at some point in the past, as one was terribly rusty and falling to bits, while the other was not bad. The back plates were in great condition, and it seemed like the pistons had been recently replaced too! So put the back end back together with copper grease and a new fitting kit. Also sprayed the new drums hammerite black to try and keep them pretty. Noted that both abs wire brackets are loose so will have to devise a fix soon.

Front brakes were also in good condition. While I was in there I got my wire brush and angle grinder going to remove all the rust. I had heavily jet washed beforehand to get rid of as much brake dust as possible too. Calipers, brackets and hubs all got the wire brush treatment and hammerite black. Also the disc hats got the same treatment and are looking good. All reassembled with new pads and copper grease in the right places. Properly torqued the wheel nuts to prevent disc warpage etc... with torque wrench. Found a dodgy wheel nut on the front - stripped threads - so actually bought one individual nut off the bay! Lol! Must have thought I was a total dork!

So with all that looking good I felt that the wheel nuts were letting it down so I got the plastic nut covers in black off eBay again. Have to admit they fit well and really finish the wheels off a bit. Good value improvement to looks I'd say!

Next big job on the list - I stripped out the old ply lining and made a start on the sound deadening, insulation, re boarding and carpeting of the van. Unfortunately I will only have completed pictures of this as I basically managed to do the whole van in about 4 days of after work effort. Basically, it's exactly the same job as sitdownsurfers camper conversion.

I firstly used the flashband from B&Q to heavily cover all the large flat areas. I did go a good bit heavier on the flash banding than mr surfers as I bought way more than needed - bit of an overestimation on my part and thought it might as well be on the panels and not on the roll! Used recycled bottle insulation in all the gaps I could squeeze it into. Then between 3 and 5 layers of foil faced bubble wrap. Used foil tape to seal the edges. Ply was then templated and cut, checked, adjusted, carpeted and fitted. I put a few layers of bubble wrap on the backs of the ply too. I used the smoke grey mega stretch carpet from mega van mats. Have to admit their glue is fantastic - much better to work with than evostick stuff. I attached the ply with 3mm pilot holes and some screws.

Floor is flashbanded, then a double layer of spare foam carpet underlay I had from the spare room, then 18mm ply and a nice grey carpet tile bonded down. Sides are 9mm ply. Roof panels are 6mm ply.

Initial impressions from road test? - Awesome!!!!!! We could not believe the difference. Basically it's like an acoustic black hole behind your head! Even up to full motorway speed. Conversations are 100 times easier. No more rattles, thumps or squeaks from the load bay, no drumming or echoing. You don't hear other cars until they are ahead of you on the motorway! The big problem though is what you hear ahead of the van now! I can now really hear every noise the engine makes. The clutch thrash is definitely more noticeable. You notice the road noise from the front wheels more. You even actually hear the drumming of the doors!! So I bet you can guess what my next jobs are ;-)

If you haven't already done this, it's well worthwhile!
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby mishnish » Wed May 28, 2014 9:59 pm

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Some pictures of the lining. Well pleased with how it turned out!
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby Mr RVM » Wed May 28, 2014 10:06 pm

And so you should be, it looks mint, absolutely crackin job :!: :)
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby frank308d » Wed May 28, 2014 10:11 pm

Bloody nice work on the trim mate. Veltrim?
I've got a semi
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Re: Vanzilla! An 05 Connect LWB boating battle bus!

Postby RustWidow » Wed May 28, 2014 10:38 pm

Good job, looks great
Old Fords Never Die - some fool keeps repairing them
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