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mk4 camper/day van

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mk4 camper/day van

Postby mike En » Sun Jun 26, 2016 1:07 am

Hi all, new to the forum.
This is my mk4 camper. Bought it about 6 weeks ago as a pretty straight van. Was resprayed in 2010, had £1200 worth of weding before this, and a further £1400 in 2012 !
The previous owner ran it for a few years, then decided to strip the rear out and fit a new interior, he bought Mazda bongo seats/bed but that was it, never fitted them, he got ill and the van sat in a barn for 4 years.

Since getting it I've removed the rest of the panels from inside, removed all the old insulation (and dead mice !)
Have made new door cards and side panels from 6mm ply, have fitted the bongo seat runners today, new black acoustic carpet is on its way for the roof and top half of the side's, and some vinyl is on its way for all of the ply panels.
Will then be making some storage and the back bongo seat, behind the driver and passenger seat,and over the tops of the rear tub's.
Have also bought a pair of recaro trend seats for the front (£40 from local breakers), drivers seat is already in.
Also got a set of 15" steel wheels with good tyres and proper ford hub caps off ebay for £1 !!! Going to tapper the bolt holes so I can run them on this.

Here's a few pics (if I've done it right lol)

WP_20160523_19_39_07_Pro.jpg


WP_20160523_19_38_50_Pro.jpg


WP_20160621_16_50_09_Pro.jpg


WP_20160621_16_48_59_Pro.jpg
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Re: mk4 camper/day van

Postby mike En » Wed Jun 29, 2016 7:33 pm

Had a spare hour after work today so started covering the panels I've made, bought 5m of vintage leather style vinyl. So far have done the passenger door card and the sliding door card, pretty happy with the results.
Here's a few pics any way.

WP_20160629_19_25_19_Pro.jpg


WP_20160629_19_25_28_Pro.jpg


WP_20160629_19_26_04_Pro.jpg


Have got the day off tomoz so fingers crossed its not raining and I can carry on with it.
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Re: mk4 camper/day van

Postby mike En » Thu Jun 30, 2016 11:16 pm

So today I built the floor, I've raised it up to cover the rails that the bongo seats ait on, bit of a fiddle cutting slots for the wood to sit over the brackets on the rails but its all in a screwed down.
Couple of rubbish pics but you get the idea.

WP_20160630_15_31_33_Pro.jpg


WP_20160630_15_31_46_Pro.jpg


Trip to the scrap yard tomorrow on my way home for work to have a look for some rear seat belts and other randomness lol
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Re: mk4 camper/day van

Postby transitandy » Fri Jul 01, 2016 11:15 pm

Nice work m8y :)
Lovely mk4 as well 8)
TRANSIT M8, SAY NO MORE YOUR IN...... FORD THROUGH TO THE BONE......
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Re: mk4 camper/day van

Postby mike En » Sat Jul 02, 2016 1:09 am

transitandy wrote:Nice work m8y :)
Lovely mk4 as well 8)


Thanks mate.

Hopefully have a day on it over the weekend to start fitting some more bits.
Have got a central locking kit, 3x led roof lights (front, middle, back) and pair of 6" speakers to go in and then rear seat belts to fit. Can then carry on trimming the insides.
Want to change a few exterior bits aswell, swap the front and side indicators to clear lenses.
Would like some different wheels, possibly go down the landrover steel's route.

Then next year i will be doing a full respray in a different colour. Don't mind the blue but there's a few scratches and chips here and there, plus rear door is on its last legs so that needs replacing before then. Also would like to find a chrome A var and side rails to "bling" it up a bit.

Also have another project to get finished (mk2 golf with 1.9 diesel conversion)
mike En
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Re: mk4 camper/day van

Postby transitandy » Sat Jul 02, 2016 9:44 am

You going to transitmania in august :?:
TRANSIT M8, SAY NO MORE YOUR IN...... FORD THROUGH TO THE BONE......
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Re: mk4 camper/day van

Postby mike En » Sat Aug 20, 2016 11:44 pm

Getting close to finishing now !
Put it in for an mot, failed but I knew it would.
Battery wasn't clamped down properly. Tray was rotten and fell apart, have replaced it with one from a mk3 vw golf.
Hazards were only working on one side. Have pulled wiring and relay about and now work fine.
Then, welding, welding and more welding ! Lol.
Front upper shock mount has a few holes, couple of small patches on the sills and a bit on the front wishbone mount, should get it all done tomoz.
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Re: mk4 camper/day van

Postby Luke » Sun Aug 21, 2016 11:52 am

smart looking mk4 8)
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Re: mk4 camper/day van

Postby mike En » Tue Aug 23, 2016 7:25 pm

Thanks mate.

Now has a years mot on it !

List of jobs to finish before I tax and insure it on the 1st of September are:
.fit the floor carpet
.make the second wheel arch cover/box
.make the upper rear panels, trim them, then fit them
.carpet both arch covers/boxes
.couple of small bits of trim to make where the sides meet the roof
.remove the steering wheel and put it back on straight !
.wire in isso blocks for the stereo to get rid of the twisted and tapped wiring !

Will take some more pics at the weekend after the above things are done.
mike En
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Re: mk4 camper/day van

Postby mike En » Thu Aug 25, 2016 1:33 am

This is one bit of rust I had to sort out, made the replacement parts from scratch, I don't believe in buying repair panels only to chop them up and use a small piece ! Lol.

WP_20160812_10_14_03_Pro.jpg


WP_20160812_10_14_35_Pro.jpg


So sorts that, then had this bit to sort out, inner and outer sill, outrigger and also the inner arch needed repairs.

WP_20160821_16_07_42_Pro.jpg


Plus more on the front chassis rail where the wishbone mounts on, upper shock mount area and more on the sills.

2 days and 3 mig welder's later and its all sorted ! (mine broke half way through, borrowed another which was crap, then rented a 3rd !)

Anyway tonight I've fitted the floor carpet and finished a couple of other small bits. Tomoz will be the big push to finish ! For now I'll leave you with this pic.

WP_20160823_19_40_48_Pro.jpg
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Re: mk4 camper/day van

Postby mike En » Sun Sep 04, 2016 8:47 am

Has now been out for its first camping trip ! Went 200 odd miles, up to Norfolk, around and then back the next day.
Only issue has been the clutch auto adjuster slipping every now and then when pushing the pedal down, bit annoying when it done this when in 1st gear coming out of a parking space as didn't want to come out of gear ! A few gentle pumps on the pedal and it was fine again. Also side opening windows are a must ! Have some waiting for me to swap with my fixed ones already so will do that next weekend.

Also on going to get a mk5 manual adjustment clutch pedal.
mike En
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Re: mk4 camper/day van

Postby mike En » Sun Sep 18, 2016 9:15 pm

Had a look at the clutch pedal, took it off expecting to find warn teeth and full of dust, was clean with no signs of any wear though ! Although I did notice there was a lot of side ways movement on the pedal where it pivots on the pedal box, have fitted extra washers which has got rid of the wobble. Has been no more incidents of the adjuster slipping since doing this.

On another note I've picked up some landrover Weller steel today, won them on ebay for 99p ! With tyres which I'll sell to a local
farmer !

Heres a few more pics of the van since it was finished (ish lol)

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WP_20160827_19_10_29_Pro.jpg

WP_20160827_19_09_48_Pro.jpg

WP_20160911_16_40_01_Pro.jpg

WP_20160918_13_09_26_Pro.jpg


Got to fix the wiper linkage aswell, passenger side stopped working the other day, has broke the end off part of the linkage.
Don't know if you can replace part of it or the whole linkage all fixed as one ???
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Re: mk4 camper/day van

Postby mike En » Mon Sep 19, 2016 7:22 pm

New steering wheel and boss turned up while i was at work today so just fitted them. Not bad for £15 inc delivery.
Retro astrali from 1978 !

WP_20160919_18_28_06_Pro.jpg


WP_20160919_18_34_42_Pro.jpg


Looks a lot better than the original one. Now I've got a bit more space for my legs aswell :)
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Re: mk4 camper/day van

Postby mike En » Sat Sep 24, 2016 11:27 pm

After buying a set of Weller steels for 99p I've just won another set for £9 but this time very good condition chrome ones !
Will be picking them up next week after work, then repaint the white wellers and drill both set's to try on the van.

Have picked up a mk5 clutch pedal and manual adjust cable so will change that.

Also ordered a flush fit mains hook up socket, already have a choice I've 4 consumer units I've acquired from work so will be running mains power inside during the week.

On another note I need to re glue part of the rear head lining as a small patch has dropped in the hot weather. And reglue the front insulation to the roof as it's also dropped, pushing the roof panel down about 2".
mike En
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Re: mk4 camper/day van

Postby mike En » Fri Sep 30, 2016 7:14 pm

Fitted my mk5 clutch pedal and adjustable cable today, what a difference ! Drives so much better now, clutch is a lot more positive aswell and I don't have to worry its going to slip anymore ! Still a slight crunch on down change in to second but fine if done a bit slower so can live with that ! Next job is going to be tracing where the small oil leak is coming from (possibly sump gasket) and giving the engine a damn good degrease and clean as it stinks of old oil when hot ! Also filter and oil change at some point.
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