The 4X4 Postal CamperVan Project
Last updated Jan 2019
Apologies THIS WHOLE SECTION IS A COMPLETE MESS
The idea : Build a campervan, for all terrain exploring, diesel powered, based on the Kubvan.
Lots of folks have put VW Diesels into Toyota 4X4's for obvious reasons, however putting a VW diesel and Toyota 4X4 running gear into Grumman Kubvan is another story. Here is a repository of details
The original Kubvan
configuration included a normally
aspirated water cooled 1.6 litre VW diesel and an automatic
transmission, with all VW rabbit running gear. The Grumman Kubvanis
aluminum body and frame, with the vw rabbit front
wheel drive. A cool
So this prohect includes : Stretch the van body 18 inches to allow for more comfortable sleeping Remove and recongure the fuel tank to allow for a portion of the floor to be lowered in order to facilitate a sitting area.
The motor is going to be replaced with a 1.9 litre VW AHU turbo diesel aand mated with a toyota 4X4 transmission. Its all going to sit on a toyota front and rear axle and suspension.
2010-2018:Not in chronological order.
Spentthe first two years learning about 4X4 construction, by dismantling several vehicles and have ended up with a toyota transmission, and a front & rear differantial for the project. After some debate I also settled on using the VW 1.9 TDI for the engine instead of the Toyota Diesel mostly because of the physical size of the engine and my familiraity with the VW engines have had in the Kubvan since 1995.
Getting the frame rails and bell housing clearances sorted out. Looks like I will be building a front end frame rail that connects to the existing body frame rails. The new frame rails will provide the engine mounts, pick up the front of the leaf springs and tie in the shock towers to the body. The fire wall will need to be cut away to provide space for the bell housing.
|Kubvan engine compartment showing end of frame rails and front wheel wishbone connection. The rack and pinnion steering is still on the fire ewall and still needs removing. Inside frame rail dimension 24 inches, sufficient for longtitudenal engine mounting. Will try to use existing brake system & the Toyota steering mechanisim.
Frame construction :
the left :
Outside frame rail dimension between rails = 29 inches, just enough to pickup spring hangers on bottom of rails. Front of body connected to rails. A beam across the front will tie it all together. New engine mounts will be mounted on inside of rails.
and beam across front
cut and test fitted next step is to fit the front
springs and shocks. I cut
the front spring hangers off the old toyota frame to reuse here.
On the right : frames ready to slide under body and connect in to the original frame.
|The body stretch
|Need 18 inches of additional interior space to make it comfortable to sleep in, we also needed some frame rails to tie the rear suspension in.
18 inch panel
Rear frame extended for longer body and
18 inch extension
18 inch stretch, note extrusion extension.
New Handle from a bigger Grumman body:)
Sitting on the wheels
Found a tranny, thanks Derek.
Was a bit of a challange as you need a bell housing off a different car to match up with the ACME VW to Toyota adapter plate
With the VW engine you need the bell housing on the right to allow space for the starter motor.
4X4 Tranny showing power take off
Adapter plate from acmeadapters.com attached
Engine 1 in Bay, this is not the final engine we used. Just used for building the engine mounts and figuring out other details.
Left side rear engine mount using original rabbit rear mount. Bolts are only for mock up prior to welding
Right side front engine mount, from another vehicle.
Steering rod, gear box connections
|This seems to line up nicely but the mounting my be difficult. I have a mustamg II rack and pinion that others have suggested would be a better solution. It however has other configuration problems.
Cab, interior views
Driver and passenger area after removal of fuel tank.
Tranny Installed, drive shaft connected to diff.
Rear trannty support.
Engine ECU :
This continues to be a work in progress, but the ECU is connected, the motor is running nicely and the fly by wire throttle works as you can see from the video below. Below also you can see the Mk3 Instrument cluster working. Next step is to connect the cluster, steering column etc. I am hoping there is a tach output from the ECU, and that the oil pressure and glow plug light function correctly once the engine and ECU are connected to the cluster. ECU documentation below.
LOOKS EASY WHEN YOU GET THIS FAR.
Click for PDF
Original VW Jetta Mk3 instrument clusterSo this was a major piece of research and even more testing but finally, I figured it all out got all the indicator lights to work as wella s the fuel gauge and coolant temperature.
click for a PDF
Finally working all lights on and gauges deflected 50%
breadboard U1 and U2 from the relay block
Checking gauges and grounds
Figure this is interesting for those that have never had one apart
An invaluable link to figure out the cluster connections: http://www.a2resource.com/electrical/CE2.html , http://www.a2resource.com/electrical/CE2cluster.html
LINKS: I have found these sites and forums to be helpful along the way:
Toyota service manual downloads : http://daemon4x4.org/portal/downloads.php?dcid=17&p=1
All ya wanted to know about diffs: http://home.4x4wire.com/erik/diffs/#top :
Shackles : http://www.4crawler.com/4x4/ForSale/Shackles.shtml
Rivet : Rivet Gun Notes and Riveting Tips
A great local site with very helpful people : http://island4x4.com/
Toyota diesel: http://www.toyotadiesel.com .
Toyota drivetrain specs: http://www.4x4wire.com/toyota/faq/parts/
Toyota Differential ID:http://www.off-road.com/trucks-4x4/tech/toyota-differential-identification-18588.html
Toyota VIN number lookup and parts lists : http://www.toyodiy.com/
Toyota Manuals : http://landcruiser.grundahl.ca/Toyota%20Manual/Drawings : http://www.drivetrain.com/parts_catalog/manual_transmission_overhaul_kits/toyota_manual_transmission_illustration.html
Toyota Timeline, changes to design over the years: http://www.4x4wire.com/toyota/faq/
RF1A, Top shift mod: http://www.toyotaoffroad.com/Articles/Projects/TopShift/TopShift.htm
A really great Link about diesel conversions: http://vpiza.org/~jmeehan/toyotadiesel/