I'm about 3 weeks into this now and have been documenting with photo's as often as I remember to, so thought it time to start the build thread and let you know what's happening.

So we started with a circa 150k miles 2002 LWB T4 panel van.
Owned by 'the firm' pretty much from new and had a hard working life but hasn't really wanted for anything mechanically.
Just very very dirty.






I had the choice of two, and frankly this is the worst but it has electric windows and mirrors and captains seats up front, so that swung it for me for which one to keep. The other one doesn't need anything like as much bodywork but a repaint and colour change is on the cards so it seemed to make sense to go with the one. the intention is that a full camper conversion will follow.

Good luck will watch this thread

So lots of grime, missing trim and general neglect to work on






Started by ripping out the racking:






More grip fill than you can imagine, but eventually we got to this:




It's clearly been ply lined and floored from brand new and behind the lining it is absolutely mint - just a bit dusty!! Proper result.

Meanwhile - I 'salvaged' a tailgate and ditched the double doors. Sorry no pics of 'in progress'. Putting the tailgate on mine was reasonably straightforward, but putting the double doors back on the van I 'robbed' the tailgate from was much less so. Still it was the right thing to do and I had loads of help from the guys down at New Barn Cars to sort this. I think it was worth it though as I'm planning on this being a 'keeper' and a tailgate was on the wish list so needed to be done.

If you're looking to fit a tailgate to a double door bus then there is a really detailed thread on the T4 forum for all the why's and wherefores of how to fit the tailgate. No such thread seems to exist for fitting double doors to a tailgate model and I thing there's a bloody good reason for it! The double door refit took 3 times longer than the tailgate swap.

It's now in for paint.

We're going with a metallic grey to match the Golf (VW Slate Grey ish) and work is in progress.
I've left a camera with the painters and even though I've got some photo's from my visits to have a look at progress I'll save them until It's all sorted and I can post them in sequence 'start to finish'

As they strip it down I'm working on the trim to clean it all up ready for the refit.

It's all pretty grimey but seems to be coming up quite well. the problem is lifting 10 years of accumulated grime from the 'grain' of the plastics. I really don't want to paint the internal plastics - personal choice but I just don't think they look right when painted so I'm going to persevere with the scrubbing!

Wish I would of converted my t5 proper now. Money and as was a work van couldn't really afford to.
Looking good under that ply. Keep up the scrubbing.
I know the grey you on about like it!!

bugjammin wrote:Wish I would of converted my t5 proper now. Money and as was a work van couldn't really afford to.
Looking good under that ply. Keep up the scrubbing.
I know the grey you on about like it!!

Thanks fella. I'm lucky that I don't 'need' to 'use' the van so I can manage with it off the road in pieces for as long as it takes......but now I've started I'm desperate to get it done...

Right - interior trim cleaning. the black stuff is OK 'cos you can scrub it with a nail brush to remove the crap and then re black it with some of that 'bumper black' stuff. The door step inserts came up a treat.
Before


After


The door handles weren't too bad either.
Started like this



And are currently like this. They have a smooth finish which makes them easier to clean - although these have now gone to my father in law (www.williamsmetalpolishers.co.uk) to 'polish' and will hopefully come back 'like new'. He's dead good at stuff like that



The door cards are proving to be much more troublesome. They have discoloured on the top edges and there is proper filth in the grain of the plastic. I'm going to try a wallpaper steamer to see if I can lift some of the crap.

General scrubbing has got me from here


to here


But they still need to be cleaner.

Looking good Neil We're ready to put ours in for paint soon too. What's you plan for windows? I think we'll be using tidytransporters as they're local to us and seem to get really good feedback

negawskloV wrote:Looking good Neil We're ready to put ours in for paint soon too. What's you plan for windows? I think we'll be using tidytransporters as they're local to us and seem to get really good feedback

Thanks Ben

I've gone for the VW ones from TPS. They were £122 all in for the pair. They dont come tinted, but I need to tint the tailgate, so I figured if it was all done by the same chap they'd all end up with the same tint.

The glass fit and tinting is bieng done by the chap that has removed the glass for the paint shop and will be refitting the windscreen/ tailgate glass.

Nice one , coming on well , I know all about getting the dirt off the pannels I painted my steps and some of the floor bits very ligtly and they cam up great .

Wheres TPS mate ?

Toastie wrote:Wheres TPS mate ?

Trade Parts Centre - the VAG group spares distribution centre in Tewkesbury

Gloucester TPS
Unit 7 Alexandra Way
Ashchurch Business Centre
Tewkesbury
Gloucestershire
GL20 8NB

Tel: 0845 812 5440
Fax: 0845 812 5441

tradesales@gloucestertps.vwgtps.co.uk

Opening Times
08:00-18:00 Monday to Friday
08.00-13.00 Saturday

Ta

that's a good price for the windows Neil Tidy quoted us £260 to supply & fit 2x OEM windows but I'm tempted to go for privacy glass and maybe a slider on the O/S above the hob for ventilation

I did look at sliders, but they were a bit pricey and the budget is tight so thought I'd better spend the extra elsewhere.
I'm going to go for a 'pull out' rear kitchen that slides out from the 'boot' on drawer runners as I dont really like cooking in the van.

All looking good Neil well done !!

negawskloV wrote:Looking good Neil We're ready to put ours in for paint soon too.

Ben - are you sticking with the red or going for a colour change?

Looking good

weardybeardy wrote:

negawskloV wrote:Looking good Neil We're ready to put ours in for paint soon too.

Ben - are you sticking with the red or going for a colour change?

debateable at the mo I'm fairly certain we'll be sticking with the red to keep the cost down (avoiding painting the interior) but we still need to make a final decision.

More cleaning




And some spending

Looking good! What did you use to clean your sun visors?

Jif, gentle use of a scotchbrite pad and a nail brush and then a quick rise under the hot tap!
Some d**k has written his PIN number (or it could even be the radio code) on the inside of the drivers side one in biro and it doesn't want to come off. I've managed to fade it back with sparing use of neat bleach so it's not so obvious but you can still see it.

Yeah ours has phone numbers written all over it too. I bought another set but they're grubby and need a clean.

More expense!!
Badges from Transporters R Us
Mudflaps actually worked out cheaper getting originals from VW



The van should be out of paint by the weekend so I can start bolting stuff on.

I left a camera with the paint shop to document progress

Looks like it was a bit dusty in there!