Bruce Vanner! Long, Slow Vanagon Transformation

vwhammer

Adventurer
I do love the platform.
I keep thinking that it won't work for this or that so I start looking at or designing something new and I always end up back to something like this.
Its just big enough and just small enough.
In my opinion is really is the most efficient off roader you can camp/live in.
Well once you make it a proper off roader.

Many have proved that with a few select pieces of equipment you can live out of one of these things indefinitely.

My wife and I made the decision to move out west once we wrap up a few things in Ohio.
My plan is to build this van and be the first Vanagon (that I know of) to cross the Trans America Trail from coast to coast ending in our new place of residence.
 

MikeCG

Adventurer
Don't know if your looking for a power boost or not, but I know swapping subaru engines into the Vanagons is pretty popular. I think they use the EG33 out of the 1992 to 97 SVX.
 

vwhammer

Adventurer
Well I guess it has been a while. A lot has happened in that while.
It's a long story but it involved a plan to move out west which led to a halt in all Vanagon activities so I could focus on ridding myself of anything and everything that I had no intentions of dragging with me.
The plan was to sell everything that would not fit in the van and my wife's Audi wagon and roll out.
Obviously this would have involved finishing the van before leaving.

Sell things I did and plan for the departure I obsessed over.
However, more silly life stuff got in the way and those plans were put on hold.

My jobs sucks.
My wife's jobs did not and it paid well enough that we began to rethink the whole moving-out-west thing.
We decided to hold out a little longer and eventually decided that buying a house made sense...or did it? Only time will tell.

We bought a house and dragged my dear old Vanagon to the new garage with its finished front big brake set up and no engine.

Buying a house was a big deal for us and has occupied a lot of time.
It turned out to be more time than I really cared to waste but felt it was necessary to get a space (using the term loosely) to properly build what I have in mind.

I have not forgotten about the van project.
Actually since moving to the new place my primary objective has been getting the garage "fully operational" (in my best Darth Vader voice)

The garage had no electric, which I have installed and naturally no lights, which I have also installed along with some shelving and a fine ***** work bench.
Ok. It's "A" work bench but its a start.


Somewhere in this confusion I came across a beat old Subaru that needed my attention and would serve as a perfect replacement for my even more beat even older Subaru.
I lifted it a couple inches and put some beefy meats on it and called it a day.



With that out of the way the focus became the van... Or so I thought.

The company I work for so graciously decided to give me a little time off and that threw yet another wrench into the plans.
I have been laid off since January and the goal now is to get some kind of business off the ground so I never have to work for another shi...crappy company like that ever again.

This leads us to about where we are now.
I am in the process of selling off a couple of other projects for funding and ironing out all the wrinkles so I have a solid game plan.
I had planned on plopping a plain, old, reliable Subaru 2.2 in the van but have since decided that I need more juice for towing duties.
I have thought about a VW TDI and even the venerable small block chevy, in 5.3 vortec trim of course.
For now I am focusing on the suspension, axles and four wheel drive lay out.
If it all works out I will be able to use any engine and transmission combo I choose.
I guess keep a relaxed eye on this thread for more updates and wish me luck in the battle that we all call life.

Until next time...
 

vwhammer

Adventurer
Yet another update on the looong, slow Vanagon transformation thread.

Geez. Where do I start.

Well, for starters I was called back to my job.
I know. I know. I should feel blessed or grateful or whatever but, "A", I am not a religious man, "B" this job sucks and "C" this means I cannot spend all day in the shop making this whole thing work.

Before I had all this time and no money and now I will have money but no time.

Anyway, I started back last Monday but not before selling some things and buying some other things.

I sold my motorcycle and that lifted, green Subaru shown above.

This gave me a little cash to play with until the paychecks start rolling in.

My time may be short in this state so I have decided to skip stage one and two and go straight to stage three.

As I mentioned in my second post in this thread, stage three gets pretty involved.
I can not elaborate too much at this time but I did get a couple of the more serious bits needed for old Bruce's transformation.
Hmm that phrase does not paint a pretty picture in my head but I digress.

I think I managed to find the crustiest FJ80 axles this side of the Mississippi.


They are both equipped with factory Toyota E-lockers but will likely need a thorough tear-down and clean up before they can be called into service.

However, as they say across the pond, they were cheap as chips and left me with a fair deal of cash from my axle budget for cleanup and repairs.

I will be stripping all of the factory mounts from the housings for nearly everything so I figured why not bust out the sawz all (AKA reciprocating saw) and whack off.... remove some of the offending bits before I even get them off the trailer.

Heck the rear already looks better.


I will lug them off the trailer sometime this week and really start tearing them apart.

While I was at it I also managed to score another important piece of the 4x4 puzzle.
No rig can claim true off-road-capable-status without a proper transfer case and for the money you would be hard pressed to find a better case than the Land Rover LT230.


It is gear driven with an aluminum case and its 3.32:1 low range is about as good as it gets outside of a Jeep Rubicon or Atlas case.
Its 1.2:1 high range means I won't have to re-gear the axles for the meager tire size I plan on running.

I should also point out that these are available all over the place because the poor old Discoverys that they came from usually quit running and are abandon long before the transfer case is even broken in.
Yes. That is a dis against the D1 and D2.
"How dare he" you say.
Well, I owned one and Land Rover should be ashamed of themselves for releasing this abomination on the public; at least the US versions anyway.

Mine would not work for more than two weeks at a time before needing serious repair.
Ok maybe I got a crappy one but.... well there I go getting all off topic again.
Back to the topic at hand.

As some of the more astute viewers may have noticed in the pic, I have opened the back side of the case that is usually reserved for a PTO output and will be making that my new input from trans to case.
I have to fab up a couple of parts but this will give me the proper passenger side drop in a rear engine configuration that I will need when the axles are under the rig.

I have some more parts coming and will likely update this when they get here but for now I need to focus on getting the axles cleaned up and transfer case ready to rock.

Until next time...

P.S. I am looking for a 96-2000 Toyota 4Runner rear E-locker if anyone has one lying around.
 

Johny5

Adventurer
Looking forward to see what you have planed. I have always liked these vans but could not stand the lack of power
 

tgreening

Expedition Leader
Don't be too bent about going back to that job. There's a few things to be said about "working for the man", the biggest being that at the end of the day you can punch out and leave it behind. Start your own biz and I guarantee you that won't be the case. Be your own boss is a myth. Every time your phone rings, it's your boss(es). You go home and worry about getting a job done, finding the next job, paying the bills, taxes, insurance, on and on and on top of worrying about all your home expenses/issues.

It can be good, or it can be a nightmare, but it will never be the bowl of cherries many people think.


You called that subi a beater? Holy crap, what do you consider cherry? :)
 

vwhammer

Adventurer
Well I got a couple more packages.

Found a pretty good deal on some 235/85R16 General Grabber AT2s.
Had them mounted on some 16x7 FJ Cruiser Steelies.


They are a fair bit bigger than the stockers.


Its going to have to sit a fair bit higher to clear these babies.


I plan to keep it as low as I possibly can without cutting up any major body parts.

The piles of parts in the garage is going to slow me down a little bit.
I also bought a new air compressor and plasma cutter so I am going to have to take a couple days and get wiring and plumbing in the garage for that so I can get it out of the way and get things put back in their place so I can actually move around enough to work.
 

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