T4 Synchro Doka Build

whatcharterboat

Supporting Sponsor, Overland Certified OC0018
Looking for any advice from other T4 Synchro owners please.
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I am hoping to build this into a neat travel rig over the next year or so. This '95 model Doka was a gift from a very old friend. There was a bit of rust in the body and almost 600k'k's under it's belt so he decided to try to find a cleaner one. The truck had always been serviced but has done some very hard yards as a builder's work horse. To make it worse, he only lived a few hundred metres from the beach. Actually The rust is quite minor really....the underbody and rear subframe are as clean as a whistle.
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So anyway he ended up with this one as a worthy replacement. It's a naturally aspirated diesel model around the same vintage as mine. He just fitted these custom made rims so he could run 265/70R15's. I've currently got 235/75R15's but hope to fit 215/85R16's if that's feasible with the gearing but more about that later. Here's my mate's new truck . >
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So after getting it home I got the kids to start cleaning it out and we made some assessments. I wasn't real crazy about the clipdeck alloy tray so that came off. The truck is a 2.5L petrol model but fitted with a dual fuel system. I checked the LPG tank....about 10 years out of certification so I also pulled that off.
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You've got to love that wooden spare tyre board at the front of the tray. The LPG tank was actually bracketed up to the tray and not the chassis. What a pain to get that out......and it will probably stay off too I think.
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Words cannot describe the colour of the back seat where the dogs used to ride. Hahaha.
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Realizing the amount of rust in the body, we decided that a full repaint was probably the only way to go so started ripping the thing apart almost immediately .
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This pic was taken last weekend. Hoping to get it all covered in 2pak primer/filler tomorrow after school and then rub it back on Saturday.
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Some strange looking laundry hanging up.
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whatcharterboat

Supporting Sponsor, Overland Certified OC0018
Cool project! Looks like your off to a good start.

Thanks.
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Progressing slower than I'd wished for but the results have been awesome so far. Gaps are good at the openings, body lines are straight and all panel joints were re-caulked with Sika227. Inside is all painted in the new colour and hoping to get free time and get back into it at the end of the week. Going for a matte finish which can be really hard to get an even sheen level so after painting the doorways and inside the doors, we hung all the panels back on the cab ready to tackle the exterior colour.
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Anyone who's driven a T4 will understand how much of a reach it is to the gear lever so I turned up this 11" extension which still clips into the original rubber dust boot.
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whatcharterboat

Supporting Sponsor, Overland Certified OC0018

Hi Cole......just saw your website. Awesome. Very cool logo And I saw the diesel swap on there too.
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I'm not sure how the gearing in this truck will be if I go for even taller wheels. My mate's diesel has very different gear ratios you know. Much lower first and higher 5th. My petrol T4 has quite high 1st and seems to rev a little high on the highway. I was hoping to pick up some 16" steel Vito rims and try to fit 215/85R16 or 225/75R16's. Do you have any experience there?
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Regards John.
 
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Cole

Expedition Leader
Thanks.


Unfortunately we didn't get all the variations of the VWT4 here. So I'm not totally sure on some of the gear ratios.

The largest tire I've put on is a 225/70/16. But that is mosty limited by the rear fender....a problem you don't have.
 

whatcharterboat

Supporting Sponsor, Overland Certified OC0018
Thanks.

Unfortunately we didn't get all the variations of the VWT4 here. So I'm not totally sure on some of the gear ratios.

The largest tire I've put on is a 225/70/16. But that is mosty limited by the rear fender....a problem you don't have.

Hi Cole

What rims did you use to fit those tyres? I've noticed that the offsets are critical once you get up to those larger diameter sizes. Especially at the rear of the front wheel arch.

Did you get any T4 Synchros at all?

Regards John
 

Cole

Expedition Leader
Et42-45 seems to be the ideal range.

We did not get any syncros. (but I have 2 syncro conversions in my shop at the moment:Wow1:)

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whatcharterboat

Supporting Sponsor, Overland Certified OC0018
FWIW, there is a whole thread on the wheel fitment topic here. http://www.cavevan.com/forum/index.php?topic=8.0

What a great resource for T4 owners. Thank you.

Finished the paint about 2 weeks ago but have been away camping ever since so only posting now. The glass went back in today with all new rubbers and Sika sealant. So far so good. I also picked up a new wheel cause the last one was down to a bare steel ring in places. I couldn't buy a boss for it in Australia so had to sourc one from ebay.com.uk
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