Details: REDUCED!! £27,500 ono - Open to sensible offers We spent in excess of 35k all up. We are not expecting to make a profit, it was as much about doing it and the skills learnt along the way. Whilst that might not have been the original intention, the 6.5 years over the work have added to the costs! EDIT: Location added - Located near Malmesbury, Wiltshire Kevan Hewitt - 07973 720771 Toby Davidson - 07867 569719 The highlights are The bodywork - the largest section of work. Stripped to bare metal, starting with acid dip to remove all rust and filler and give access to the previous efforts to patch rust etc on the shell. We then replaced everything that needed doing, a full list available on the website or can be shared in here in additional posts if requested. https://bert-the-van.co.uk/bodywork-restoration Rewired - new loom, split charging system. (Note: the colour is the same as the exterior. The lighting within the workshop made it look very 'yellow') https://bert-the-van.co.uk/electrics Engine rebuild - The engine was stripped down, cleaned and all components checked for wear and condition. New parts were fitted where possible to give the engine a suitable life expectancy to match the rest of the renovated van. https://bert-the-van.co.uk/powertrain Interior - One area we really went to town on was the interior. The aim was a mix of original and modern to ensure the history is maintained, but as comfortable as possible. Porsche Boxter front seats (Manual forward and back adjustment with electric tilt) are matched with a full width rock'n'roll bed in the back, new headliner, door cards, curtains, seatbelts (3 in rear, including two 3 point and a lap strap for the middle seat) etc in place, sounds mat insulation throughout, all trimmed to match by DEVON CUSTOM TRIMMERS in Barnstaple New Dometic sink and hob unit matched with a new Dometic 12v fridge. The old advert line of too much to list is true, full details of all work, parts and components are available here or by contacting either of us. https://bert-the-van.co.uk Many more pictures of Bert and the work done are on the website.
The bodywork section taken from the website Details of Work and New Parts On initial inspection the bodywork, whilst needing work didn't look too bad. However, on closer inspection it was evident that to achieve our goal of a CamperVan fit for another forty years, extensive restoration was required. But, how to eradicate corrosion and prevent it re-occurring? Eradicating corrosion After a full strip down to a bare body shell, all areas showing signs of corrosion were cut away. The body shell was taken to Surface Processes Limited (SPL) in Dudley. There the body was subjected to two processes, one to remove everything that wasn't metal I.e. paint, filler sealer etc.. and the second to neutralise corrosion. In both processes the body is completely immersed ensuring the whole body is treated and areas otherwise inaccessible were treated. i.e. inside body sections, welded seams etc. Once Bert was back home as an extra protection he was treated with a corrosion converter. Extensive online research lead us to choose FERTAN which is widely used in car restoration. Having now got a corrosion free bodyshell we set about restoring it to its original condition. New panels were welded into place and areas repaired with stainless steel plate.. New Panels fitted:- (Listed front to rear) Deformation Panel Front Panel Front Panel to Windscreen Panel Left and Right Hand cab floor Sections Left and Right Inner Wheel Arches Left and Right Hand Cab Door Outer Skins Left and Right Hand 1/4 Light Frames Left and Right Outer Wheel Arch Assemblies 'B' Post lower Section Repair Panels Left and Right Inner, Middle and Outer Sill Panels Sliding Door Lower Half Repair Panel Left Hand Complete Rear Corner Panel Right Hand Corner Lower Half Repair Panel Left and Right Battery Trays Rear Valance Outer Panel Plus other small infill panels Bodywork Restoration Preparation and Paintwork On completion of restoring Bert's bodywork to its factory condition the next steps were painting, rust proofing and sound insulation Paintwork Preparation The welded joints for the new panels were filled and sanded to create the correct profiles. The whole body was hand sanded and degreased ready for the first coat of primer. An Acid Etching Primer from UPol was used. Two coats were applied. Next came several coats of UPol High Build Primer followed by hours of hand sanding and re-priming to achieve the desired surface finish ready for the colour coat. What colour to choose. We wanted something more colourful than the original off white and a colour faithful to Bert's age and heritage. After much searching we opted for Sand Yellow body inside and out with a white roof, dash, bumpers and wheels. The actual colours are RAL 2002 and Mini Pepper White. In keeping with Bert's original finish we opted for cellulose paint which is also easier to maintain and repair. The colour coats were applied in our own custom made heated paint booth and took several days and lots of flatting and repainting to get the desired finish. Finally, the bodywork was machine polished with three grades of polishing compound to get the result you can see today. Bodywork Restoration Preservation and Comfort Rust Proofing Having spent lots of time and money restoring the body we wanted to ensure that it would last for another forty years. To help with this the complete underside of the body and the panels that are bolt to it were primed and finished with UPol RAPTER. This is a very tough coating designed to protect against arduous off road use protecting against abrasions and salt water, chemicals etc. Next the body cavities were injected with DINITROL corrosion protector Sound and Heat Insulation The body was sound proofed using the kit from SOUND DEADENING. This uses pads bonded to the inside of panels to dampen out vibrations. On top of this a layer of butyl foam is added to further eliminate sound penetration to the interior and also provides a high level of heat insulation, Just what you need in a CamperVan Bodywork Restoration Finishing Touches Having spent many months and thousands of pounds restoring and improving the body shell we turned our thoughts to the finer details of the body. New chrome handles and locks were fitted to the cab doors, sliding door, tailgate and engine bay lid to improve overall appearance and security The external appearance was further enhanced with chrome wheel trims, four new tyres and black rubber inserts for the front and rear bumpers. New Laminated Windscreen, new six window seals for all fixed glass windows New Seals and window channels for cab windows, New Cab door window glass New bright metal trims round cab door windows New Door Mirrors New aperture seals for doors, sliding door, tailgate and engine lid
Braking System Safety and Reliability go hand in hand and we wanted to make sure that Bert would provide safe as well as trouble free motoring for many years and miles to come. Bert had been stored in a barn for thirteen years so it was decided that the complete braking system should be renewed. The few parts that were being reused (front Brake Back Plates) were cleaned back to bright metal, treated with FERTAN, etch primed hand primed with red lead prime and painted grey. New Bake Parts Fitted:- Front Brake Discs Front Brake Calipers Brake Pads Front Brake Hoses Master Cylinder All metal Brake Pipes (KUNIFER) Rear Brake Hoses Rear Brake Back Plates Rear Wheel Cylinders Brake Shoe Retaining springs etc. Rear Brake Compensator This part is no longer available, however it was stripped cleaned and reassembled and refitted. A complete list of new parts is listed on the Additional Information page, and a complete catalogue of receipts is available to view by prospective purchasers. Braking System, Suspension and Running Gear Suspension The VW T2 suspension system is quite simple using torsion bars front and rear. The rear torsion bars were removed inspected and refitted. The front torsion bars were also removed inspected and refitted, all were in good working condition Suspension ball joints were inspected for end float, all OK, new ball joint boots fitted New Suspension Parts Fitted:- Both Front and Rear Shock Absorbers were renewed along with all Anti Roll Bar rubber bushes and bump stops Braking System, Suspension and Running Gear Running Gear Steering Box was dismantled examined, rebuilt and pinion end float adjusted to eliminate play in the steering. Track rod ends all inspected and found to be in good condition New Parts Fitted:- Front Hub Bearings and Seals Rear Hub Bearings and Seals
Engine The engine had not been run for many years so the decision was taken to fully recondition it. The engine was stripped down, cleaned and all components checked for wear and condition. New Parts Fitted:- Two cylinder head assemblies complete with valves etc. Cylinders with Pistons and Rings Main Bearings Big End Bearings NB Crankshaft reground by specialist Cam Shaft Bearings Eight Push Rod Tubes All Gaskets and Seals Oil strainer Spark Plugs Distributor Points Air Cleaner Element Chrome Engine Dress Kit Aluminium Air Hoses Regrettably the photos of the engine rebuild were somehow lost. A complete list of new parts is listed on the Additional Information page, and a complete catalogue of receipts is available to view by prospective purchasers. Engine and Transmission Gearbox and Drive Shafts The gearbox is the only component not subjected to reworking apart from new gaskets and new gearbox input shaft oil seal The clutch centre plate and release bearing have been replaced along with the clutch cable The drive shafts were inspected and one CV Joint was replaced along with all four Drive Shaft Boots The gear change mechanism was removed cleaned and inspected and refitted with new bushes, gear knob and gear lever travel reducer kit Engine and Transmission Heating System and Exhaust To complete the engine restoration the Heating System and Exhaust were all renewed. New Parts Fitted:- Left and Right Heat Exchangers Concertina Insulated Connecting Pipes Heater Cables Silencer and Tail Pipe All heater system gaskets and seals
Vehicle Wiring and Electrical Equipment From Bert's history we knew that in the past there had been some issues with the vehicle's wiring so we decided the safest and most reliable option would be to replace the complete wiring loom. After a couple of false starts we discovered an amazing company that specialises in VW wiring looms (VOLKSGOOD). We sent off our old wiring loom and received back a brand new loom complete with detailed instructions and wiring diagrams which are available for Bert's next owner. A split charging system kit was also fitted. New Parts Fitted:- Two Head Lights with Halogen Bulbs Side Light Bulb Holders Two Rear Light Cluster Number Plate Light Two Interior Lights All Bulbs Renewed All Fuses Renewed Interior Light Door switches Electric Windscreen Washer Kit Indicator Switch Wiper Switch Dash Warning Lights Bulbs and Bulb Holders Engine Starter Battery Leisure Battery Split Charging System Ignition Switch Key Barrel with Two Keys Fuel Tank Gauge Sender Unit Leisure Circuit Fuse Box
Interior Trim Our Mission Statement states Bert's interior had to have a 'WOW' factor. To appreciate the interior it really needs to be seen . This was the most exciting part of the restoration as we were able to deviate from VW CamperVan specifications and be creative. Firstly we upgraded the driver and passenger seats to a high back design with seats taken from a Porsche Boxster. These manually adjust back and forward with the benefit of electric rake adjustment. For the creation of the modern interior we chose DEVON CUSTOM TRIMMERS in Barnstaple. Pip did an amazing job, making rear seat cushion and rear bed cushion. All of the seats and New Door Trim Cards trimmed in matching cream faux leather with patterned inserts (see photographs to appreciate). To further enhance the interior it is fitted with complimentary curtains, tan coloured seat belts for five people and a light tan headlining. The three spoked Wood Rim Steering Wheel lifts the whole interior and adds to its opulence. The cab carpets are by MADMATZ Interior Restoration Plus Camping Equipment Being camping and Motorhome enthusiasts we wanted to equip Bert with a high degree of self sufficiency. So Bert is well equipped for life on the road. In the kitchen unit you will find a DOMETIC two ring gas hob and sink unit with electric pump and a DOMETIC 12v FRIDGE all housed in a sturdy purpose built unit made form 18mm Beech Ply laminated with Tan and Black quality Formica. The unit also houses two 10litre plastic containers for fresh and waste water and comes with a foldaway table for indoor dining. There is a matching gas cylinder locker and behind the passenger seat there is a buddy seat incorporating a large storage space it is designed to fit a PortaPotty. There is additional storage space under the rear seat and an ancillary fuse box for the kitchen and interior lights. Additional lighting is provided to create a bright living area. The lighting, fridge and water pump are powered by the leisure battery which will give several days usage in the knowledge the main battery will still start the engine when it's time to move onto the next campsite.
