Zel's Motoring Adventures...Peugeot, Renault, Rover, Trabant, Invacar, Volvo & A Sinclair C5 - Updated 09/10.

[PhilA]

...exhaust... ...weight...

Side exit.

[Zelandeth]

Side exit.

 

That's precisely what I'm thinking.  Single box after the flex joint then having it double back towards the front of the vehicle, exiting just forward of the fuel tank behind the driver's door would be the most logical routing I'd think.  There's even stuff there which would be ideal to fasten an exhaust hanger to.  Probably about 1/3 the current amount of metal involved.

[Zelandeth]

Sod it!

 

Bloody belt tensioner on the Activa's decided to start playing up.  Yes, the expensive, hard to find spring loaded one.

 

It's been "chirping" when the AC first kicks in on a warm day for a while now, but it's always been for just a brief moment then that would be it until the car was next left stopped for a couple of hours.  Last couple of days it's been protesting more, so decided to check.

 

Belt has hopped a couple of notches off the alternator and hydraulic pump because the tensioner is running out of true.

 

Great.  That's my only air conditioned car out of action until I get that sorted out.  Seriously considering just throwing it at my local garage right now.

[Zelandeth]

Having spent all morning hanging off the top of a ladder installing the automatic window openers on the skylights up here...

 

 

...by braille essentially as I was doing most of the work looking straight into the sun, I'm utterly knackered. Oh, have I mentioned that I am uncomfortable with heights?

 

So with a hundred important things to do in front of me I did the only sensible thing: went and repaired something totally trivial that hadn't even made it onto the official to do list yet.

 

 

Yep, fixed the interior light in the cab of the van. Nothing more exciting needed than a pair of new bulbs.

 

20W being burned in that alone, can see me considering an LED upgrade to that potentially in the future.

[Zelandeth]

Well had an hour to kill so went and attacked the *actual* to do list.

 

Today's target was the three dimensional jigsaw puzzle that was the toilet.

 

I know it's a Thetford Cassette unit - but the darn thing is utterly devoid of any model numbers that I can find...so finding an exact manual wasn't going to happen. I did find something reasonably close though. This gave me enough info to establish that several bits initially appeared to be missing from mine. Right up to the point where I figured out that the random pipe that I couldn't find on any of the diagrams actually connects to the central water supply - there's no flush water supply built into it.

 

What took me about half an hour of swearing to work out was that whoever had taken things to bits had turned the baseplate around. Now, it very *nearly* fits together that way around...but not quite. Once I cracked that it didn't take long to have the whole thing slotted together as it should be. Just needs the baseplate screwed to the floor and wall, and reconnection of both power and water supply. I'm hopeful that the power lead will still be tucked up under the floor. That's a task for another day though after I've finished sorting the walls out. Nevertheless, it's a "how the blazes does that fit together?!?" ticked off the list.

 

It's *really* awkward trying to work on an appliance that is precisely 5mm narrower than the room it's in. Especially when you realise you need to turn it around.

 

Satisfied with that, next up was the rat's nest surrounding the distribution board for the mains power. Everything had just been pulled out...no idea why. Didn't take long to get the feed for the mains fed DC power and the battery charger hooked back up and work out what went where. I've not hooked everything back up yet (because the tails under the van (fridge and toilet pump I'm assuming as I can't see what else would want 230V mains) haven't yet been hooked up. However once I track down a hook up cable I should be able to run things without worrying about draining the battery - and charge it without needing to haul the boat anchor out the van. I believe - need to check the wiring - that it should be possible to charge the vehicle battery through this setup too.

 

At the very least it will mean I can use power tools without needing an extension cord dangling out of the window any more.

 

Tomorrow I need to attack it with the vacuum cleaner to clear up the bits of polystyrene. It seriously looks like a snowman exploded in there just now.

[Zelandeth]

Little to report today.

 

Have had the Lada out a bit over the last couple of days. It's definitely running better than any time since I bought it. If anything I need to adjust the throttle down a bit as it's a bit *too* twitchy now if anything.

 

In the van sorting this mess out was the only real task for today.

 

 

As I'm done chopping up polystyrene sheets now there's no reason not to.

 

 

Much better.

 

Beyond that all I did was add positions for a couple of additional status indicators to the enclosure containing the mains electrical stuff.

 

These will be set up so that the amber one will show that the mains input is powered, and red to show that the output from the distribution board is live. There's an "output on" output from the DC transformer as well, I may well stick that to another one too. I'm a great fan of the whole "if it exists there should be an indicator for it" approach where electrical stuff is concerned.

 

 

There's also an element of "it's been floating around in the parts box for the last fifteen years" involved.

 

The round pin socket (it's 12V DC) will probably be replaced by a faceplate with a bunch of USB sockets. Given that virtually everything charges from USB these days that's likely to be far more useful.

 

That's pretty much it for today.

[Zelandeth]

Had this out briefly after dark, and it was downright terrifying! Quick check revealed she still had the old school pre-halogen type bulbs in the headlights. The reflectors aren't looking too clever in either, but especially the nearside.

 

Hey...look what I found in one of the lockers.

 

 

What was far more of a surprise for me was looking just on the off chance, was finding a pair of these in Halfords!

 

 

Suffice to say, there's quite an obvious difference...nearside is the H4 retrofit, offside is unchanged.

 

 

Annoyingly that new headlight is set up for a proper H4 so the bulb I've just bought won't fit. That is going to annoy me as I always like headlight bulbs to be matched sets (and generally Nightbreakers), so will have a rummage around for a new offside headlight at some point. The reflector ain't in good shape anyway.

 

Also had an unexpected visitor when I first climbed on board today.

 

 

He was safely evicted from the van, instead being relocated to the nearby hedge.

 

Definitely need to address a couple of things driving wise. There's definitely play in a balljoint (or drop link) on the offside, a definite "clonk" being heard and felt on sharp drops (the speed bumps outside Toolstation being the best example). There's also a little play in the steering box. Not Lada levels, and I'd expect it...but the handbook says to urgently contact your service agent if any play is detected...so I'll look into adjusting it if possible, and make sure it has oil in. All else fails...will keep an eye on it. It's well within MOT pass range and isn't noticeable when driving. The wiper blades are about as much use as a chocolate teapot.

 

Some of these issues may be resolved shortly. Others won't. Making sure there's oil in the steering box and replacing the centre propshaft boot will happen before the first weekend away though.

[Zelandeth]

Well I had a right surprise today.

 

I'd still been looking for a replacement for the little rubber boot on the propshaft (the idea of paying more for postage than the thing just annoys me).

 

I was passing by the (huge!) main dealer today, so figured I'd ask. The worst they'd do was laugh in my face for wandering in and asking for bits for a near extinct 28 year old van. To be fair, I was expecting as much...and being a scruffy bugger kind of expected them to look at me like an alien when I walked into their shiny showroom.

 

First surprise...nope, they treated me like royalty.

 

Second surprise: yep, they stock spares for the T1.

 

Third surprise: Unlike every other main dealer I've ever dealt with, their parts lookup system is fantastic. Even with my rubbish description, the guy had tracked down the little rubber boot in a matter of seconds.

 

"Really have to apologise sir, we don't have any in stock, I'll need to get it in from Germany. Will take a couple of days to get here. Really sorry."

 

Wait a minute mate...stop with the apologising...I don't expect you to have a truly random bit of rubber that's twenty years obsolete on the shelf... I'm bloody staggered you even have it in Germany!

 

Emboldened by that success, we tracked down the little plastic bush for the throttle cable in the arm on the fuel pump with equally ruthless efficiency.

 

I was about to walk away when I remembered one other thing I'd been scouring the internet for...one that I thought was a massive long shot.

 

...it took them about a minute to confirm that yes, they could indeed supply me with a brand new, off-the-shelf replacement for the cracked little green lens for the indicator warning light on the dashboard.

 

I was gobsmacked!

 

They've also confirmed that all the bits of the window winder assemblies are available, so I should be able to sort out the passenger one once I work out what's amiss with it.

 

I realised just after I pulled out the car park that I'd forgotten to ask about the headlight switch (mine looks like it's been used as a chew toy), will check on that when I pick the rest of the stuff up.

 

If this is a glimpse into the parts availability and helpfulness of the dealers...I can see this being a far less torturous relationship with a marque than any other I've ever known so far.

 

I know Merc do have a decent supply chain for their older cars, as they have quite a following...I wasn't quite expecting the same for a near extinct van though.

 

Thumbs up guys, well impressed!

 

Edit: Oh yeah...the prices were cheaper than I'd found online too.

[mat_the_cat]

A mate of mine in Germany has this, and is often telling me how he can still get a surprising amount of spares for it!

 

[NorthernMonkey]

Mercedes are brilliant for older bits...my 500SEC always attracts plenty of attention when it’s parked up outside the dealers among all the modern shiny shit.

In fact, it looks like someone at Blackburn Mercedes runs a tidy W123 as its normally round the back in the staff parking area.

[Zelandeth]

Right, she's officially booked into a campsite in Scarborough over the summer bank holiday weekend...so that's my deadline for getting the basics at least vaguely working!

 

Propshaft slip joint cover and brake pads should be here early next week, that should be it for the mechanical side hopefully...

 

Don't suppose anyone knows what oil the steering box wants? The handbook just helpfully states "steering gear oil" which doesn't tell me much!

[Zelandeth]

Picked up the rest of the board I need to finish panelling the bathroom today.

 

Found someone broken down in a layby just outside our neighbourhood, not ideal with two kids in child seats in the back in this heat. They had been told by the RAC patrol that their starter motor was buggered, and was waiting for a flatbed. My immediate thought was "that wouldn't have made it stop running though."

 

9.3V across the battery...well that won't be helping anything.

 

Out with the jump leads. Fired straight up, running fine but the battery light is on. Zip from their alternator, died again the moment I pulled the jump leads.

 

They were roughly 1/4 a mile from home and 200 yards from a residential side street.

 

I dragged the leisure battery out the van, bungee-corded it to the slam panel and followed them back home.

 

Seems that the alternator has packed in, and in going it's killed the battery.

 

Luckily he's still got the previous identical car (Mk I Focus) on the drive, not having got around to having it removed, so is going to pull the bits off that, and I've recommended the garage I use to get it fitted.

 

They're also going to tell RAC where to stuff their renewal and will be switching to AutoAid and saving themselves £100 a year...

[Zelandeth]

Just a quick update for tonight.

 

Was too damn hot to get much done today, not that it kept me from repeatedly trying to do stuff and immediately regretting it.

 

The initial test to see whether the portable air conditioner was partly successful, insofar as it fitted where I wanted it...but wouldn't work properly because the van was too far off level (condensate drain kept overflowing). Still, useful to know it fits. Will have a think about whether I want to actually "install" it there tomorrow.

 

Next up, start looking at getting the services under the floor back in place. This was aborted early on when the bloody ants started attacking me in organised waves.

 

Looks fairly easy to decipher though.

 

This is directly under the bathroom...

 

 

Expecting a 12V feed for the flush pump for the toilet, so that makes sense.

 

Underneath roughly where the fridge is there's this mess.

 

 

Looking in there has found a couple of 12V feeds, the level sensor for the fresh water tank, and apparently two 230V feeds.

 

Slightly confused by this, as I was only expecting a 12V and 230V feed for the fridge. I suspect there may be a separate one for vehicle battery and aux battery to handle the gas ignitor/heating element separately (I know some vans have an interlock to prevent you being able to accidentally run two systems at once - though in this case the switch handles that). Sadly I don't have a detailed schematic, so the extra wires will probably just get safely terminated in a junction box until I have time to investigate in more detail.

 

This is where I left it, especially as I discovered the hole saws I have are beyond dead... approximately two minutes after all the shops shut, because Sunday. Again, I miss Scotland.

 

I've tracked down a caravan and camper specialist nearby, so will be heading over there tomorrow to grab a bunch of water and gas pipes and the necessary fittings. Hopefully the next update will see the services far closer to being online.

 

Oh, also took the taps all out back and tested them. Glad to report that they seem to work just fine, even against full mains pressure. Even the really well jammed one seems to be just fine now water is involved and it's been operated through the full extent of its travel a few times.

[Zelandeth]

So today was moderately annoying.

 

First bit of the day involved a trundle up to a local caravan specialist. They were up front about the fact that they dealt more with the everyday stuff, and didn't have the compression fittings I needed for the gas system.

 

They did have the pipework, elbows etc for the plumbing and the supplies for the toilet and fresh water system treatment. They were also able to recommend another specialist up the road in Daventry who should have more of the nitty gritty parts in stock so should be able to fill the gaps.

 

It was half an hour further up the road. Getting there revealed one of those annoying situations where I'm absolutely sure they *had* the parts I need, but the young whipper snapper on the till was flummoxed by trying to work out bits for a van older than they were.

 

I'm pretty sure the gas connections are 3/8" (fridge excepted which appears to be 8mm), but they couldn't seem to work out what they were and wound up going around in circles.

 

I eventually ran out of patience as we weren't getting anywhere, so just paid for the new mains inlet (the lid on mine is broken) and headed for home. ...leaving the plumbing connection for the water heater inlet I wanted to find a second one of sitting by the till. Now I need two of them! Sod it!

 

Well I'll need to get a second opinion on what I need to attach to the gas manifold and just order off the internet - which was *Exactly* what I was hoping to avoid. I have honestly tried to support the local suppliers.

 

Literally as I turned into the driveway on the way home...I suddenly lost throttle again. Surprised it's taken this long to be fair, bet the screw I'd wedged the cable in when the original bush cracked has fallen out.

 

 

Yep!

 

I did have a rummage around to see if I had anything that would work to locate the cable tidily. Sadly nothing came to hand. Problem being the big shock absorber spring assembly on the end of the cable, anything to do the job had to fit over that first.

 

Instead I posted for a nice sturdy bolt and a couple of bigger washers. It's not pretty but will do.

 

 

The stress is actually still being transmitted through the shock absorber, albeit currently being transmitted through the cable sleeve rather than directly because how things have lined up. Reckon it will settle after a bit of time. I did get it sitting better after I took the photo.

 

The reason I didn't use cable ties is that I'm not convinced they'll stand up to the heat and inevitable slight diesel residue in the proximity of the pump. Metal seems more suitable.

 

First time it would up catching on the throttle linkage from full throttle so I had to have a fiddle around with it to encourage the cable to tend toward the nearside. Problems solved.

 

The throttle linkage in this thing is actually a beautiful bit of engineering. There are a lot of bits between the actual throttle cable and the fuel pump, all there to ensure that the throttle response is smooth. It really does show too, particularly in stop/start traffic and when parking. It's far better behaved than any other car I've ever owned.

 

Clever those Germans.

 

The OM.601...compact but perfectly formed.

 

 

 

(Photos were taken when I first opened things up, so the original bodge is still half present there)

 

Still can't get over how clean the engine is! Just dusty as you'd expect that is to a viscous fan blasting crazy amounts of air through the engine bay.

 

I've put a lock nut on there this time, and the bolt is wider than the slot in the cable so it can't fall out this time. I do plan to replace the bush in due course, but it shouldn't be too urgent at least compared to the rest.

 

I did notice that she seemed to have to work a bit harder to maintain speed on the motorway today...I have a sneaking feeling that the throttle cable working loose may have been behind that.

 

Despite the heat meaning I was playing Russian Roulette with heat exhaustion all afternoon I have managed to get roughly 70% of the fresh water system piped in now.

 

Tomorrow I'll hopefully get the Tee off to the water heater in, and the spur lines from there back to the shower and bathroom taps in. Then get the wastes hooked back up too.

 

Have noticed that there seems to be a bit of a weep from the top gasket on the pump... I'll get a gasket set ordered (it's quite a common and well regarded pump apparently) and swap that out if needed. It can supply a mighty impressive torrent of water though that's for sure!

 

So, hopefully tomorrow we'll have a mostly complete plumbing system. I've also drilled the holes through the floor for the wiring etc too, so can also get that lot properly routed back into the van. Once that's done I'll get the fresh water tank back into place (it will be in the way of everything otherwise, so it needs to be step seventeen rather than three).

 

Getting there! Shuffling tiredly rather than making great, elegant strides...but getting there.

[Zelandeth]

I found a solution to the problem of how to attach the water supply hoses to the water heater.

 

Turns out the thread is the same as normal 15mm compression fittings.

 

Which fit nicely in the reducers that I've got with the last half dozen or so 3/4" screw on fittings for garden taps.

 

Had a quick rummage around and found a few of the reducers in question, which I'd thrown into the box of "no idea what for, but sure these will be handy someday" items. Addition of a standard hose barb fitting as used on any garden tap prior to clip on fittings becoming the norm...and we have that problem solved.

 

 

Most of the rest of the day was spent just routing pipework, tightening up hose clamps etc...time consuming and not particularly exciting.

 

I did get to the point where I could do a quick test of things just before closing up shop for the night.

 

Went fine, right up to the point that water found its way to the water heater. At which point large quantities of it came pouring out of the water heater. Closer inspection revealed an O-ring sealing part of the heat exchanger piping to the valve body had perished. Hopefully I can find a replacement tomorrow.

 

Then I just need to sort out the waste piping, attach the taps properly, to isn't the wiring...oh...and sort out anything regarding the gas supply, which I've not touched yet as I've not been able to find the fittings.

 

No pressure!

[Zelandeth]

Well that's been a busy couple of days.

 

So we've got it as ready for the weekend as it's going to be!

 

 

 

Everything there's now working. Air conditioner was going to be taken back out, right up until it became quite apparent that it wasn't interested in coming back out of the space I'd wedged it in.

 

Oven works, water heater works (after the giant faff getting it water tight yesterday), fridge works (mains/DC only, it's not hooked up to gas yet).

 

Bathroom is still a state, but it's functional now.

 

 

Shower would have been nice to have, but there are showers at the site we're staying at at least. It's only a couple of days.

 

Oh...and I fixed this in the cab.

 

 

Nice new lens in there too to replace the cracked one.

 

Still can't quite believe that Mercedes had these available off the shelf.

 

 

Oh...and sorted the feed to the 12V socket on the dash, I'll be wanting that tomorrow.

 

Will have a chance to check the basics before we set out tomorrow, but that will be it...fingers crossed!

[timolloyd]

Good luck - amazing work!

[dollywobbler]

Happy holidays! I can't imagine a shower in a camper is anything but miserable. Wandering to the on-site showers is surely part of the camping experience?

[PhilA]

Indication vindication.

 

Good job on the plumbing, I hate pipework so can sympathize. Looking now like a pleasant place to go visiting in.

 

Phil

[Zelandeth]

220 miles later, and we're set up.

 

Van being used as intended for the first time in goodness knows how long.

 

 

Far more interesting than most of the modern tat here...

 

 

Will keep you lot updated!

[Amishtat]

Lovely to see it fulfilling its purpose and well done for all the work you've done. Hope you have a good weekend!

[cobblers]

IMG_20180809_212841.jpg

 

IMG_20180809_211827.jpg

 

 

 

That looks bloody great! I could sit in there and listen to the rain on the roof while drinking tea and beer for about 4 days. 

[Zelandeth]

Oh there's still a tonne of stuff to do, aside from the obvious bits of the kitchen and bathroom which are still outright missing...oh, and the rust...a lot of the services here are distinctly jury rigged!

[Amishtat]

You've done more in four weeks than I did in four months.. Enjoy it

[Zelandeth]

Thing I still haven't had a chance to do? Properly clean the outside of the poor thing. I have refitted quite a few missing bits of trim though. I'd hoped to give her a quick polish and wax before this trip, sadly it was not to be.

 

She's definitely getting a spruce up and coming along to a show or two before the end of the season. She's far too much of an extraordinary survivor of a largely extinct breed not to deserve that.

 

The other thing that was really tested today: hill climbing ability. 17% slope, not a problem. Granted, not in the same way that a modern would dispatch it in a squirt of boost, but while third wasn't happening, she had plenty of torque left in reserve in second, so we just took it nice and easy. No bother. Just like on an old coach, judge your pace, time your gear changes and don't get greedy. You're not going to whistle up there at 60, trundling sedately at 25 isn't going to cost you too many seconds of your life.

 

Did have one issue this evening - just got the bed set up, then turned around, and this happened.

 

 

We did eventually come to an arrangement though. Even if it does mean I'm laying at about 30 degrees across the bed.

 

Now having a quiet evening, laying in bed, watching The Martian, which seems somehow appropriate.

[Zelandeth]

Despite one slightly dodgy foot and a highly fashionable duct tape patch, the awning works! Hadn't touched it until yesterday.

 

 

It's meant to be tipping it down all day today, so having somewhere to stick shoes that are wet and such seemed worthwhile.

 

Like everything else on the outside of the van, it too needs a really good clean.

[dozeydustman]

That old bus looks pretty good Zel. I think you've got a good'un with all the work you've put in making it decent inside. Well done sir.

[bezzabsa]

is that Decking boards underneath??????????????????????????? 

[Zelandeth]

is that Decking boards underneath???????????????????????????

Yes.

 

Decking made of what appears to be the densest wood known to man based on how hard to cut/drill through they are.

 

Replacing them with something slightly more appropriate is on the to do list. For the time being though, they're doing the job. The flooring for the last three feet or so of the living area has been replaced, I'm guessing due to historic damp issues.

 

Whoever previously worked on this van was big on durability, not so much on trying to strike a balance between resilience and weight.

 

Some of the framework repairs in the bathroom wall are made of some wood that's about as difficult to drill through as titanium and weighs about as much as lead.

[Zelandeth]

Back home now, just over 440 miles covered there and back.

 

 

Glad to report that the van didn't miss a beat in any way the whole weekend. Even my bodges held up just fine.

 

Also have had the opportunity to calculate my fuel usage on the way out - came out to 23.6mpg. I don't reckon that's bad at all for such a heavy brick that makes a shed look aerodynamic. Figure is probably slightly higher actually as I managed to get more in this time than when I filled up before the trip.

 

EDIT: Having noticed that the bass line under load had become distinctly louder during the trip I had a closer look. Yep...that split in the silencer has indeed got quite a bit bigger.

 

 

Definitely need to sort that sooner than later. Will drop by some exhaust places this week, see how baffled they are by quoting for something that's not a sports car (or pretending to be one). Can't hurt to help her breathe a bit more freely...and probably won't have a bad rumble with a more appropriate amount of silencing.

 

... I'm seriously tempted to get a few standard bits and build an exhaust myself, given that the available space negates a lot of the normal car exhaust headaches...but also feel she deserves better than my bodging. Plus the guys doing this are more likely to have some idea what will work best in terms of silencer types.