Tigger Reborn

Just thought I would start a build thread to keep track of what I'm doing.

Not your stunning air-cooled stuff I'm afraid but its part of the family to us.

Had it 7 years now and this will be its third reincarnation.

Started as an AA Combi T4 Van

I fitted it out in Caravelle interior panels and rear seats. Orange paint job.

Next was a Styleline interior with a T5 Caravelle rear triple seat on rails that we used as our bedroom when camping and had it set up with an awning.

Now its out with the Caravelle triple and in with a Variotech 3/4 RnR seat and camper units.

This will be quite random as I will post up pics as and when bits get done.

Headlight Mods and bonnet.

As we know, T4 headlights are krapp...

Couldn't bring myself to buy a set of tacky DRL "Audi style" lights so set about creating my own.

Sourced some independent light units that are designed for the truck market and fitted them out with 12v lamps.



I used the original headlight surround so it will still hold the indicators and fitted a steel plate to hold the lights

Found that I needed more movement so had to profile the plate to suit.





Modified a bonnet to get a more modern looking style so blended out the steps around the headlights.



Fitted and adjusted on an MOT station to get the positions right and had the bonnet sprayed when I had the van arches replaced and re-sprayed.





Next to do is the surrounds/in-fills and an upgraded wiring loom. But that has to wait.  

Next was the seats.

Bought a set of cream leather seats from a guy on eBay and the turned up GREY!!!

After a battle for a refund, I decided to put the money it would have costed to pallet them back towards a re-colouring kit.

Never attempted re-colouring leather before but thought I'll give it a go.

The results were a lot better than I could have imagined and I am sooo chuffed...

Sorry no pics of them grey but here they are part done.







Re-assembled ready to be fitted on the cut down and swivelled bases.





And here fitted in the van

Looking good Amigo

Had a pair of half size Reimo seat rails that were never machined so took them to a friends workshop and milled out the slots to drop the seats into the rails and 3 holes to locate the seat in 3 positions. First hole right back so the seat is as far back as possible giving maximum room when camping during the day. Second hole located so seat is in correct position for seat belt (travelling mode) and third forward in correct position for making into bed.

These were marked out and remarked and re checked about 10 times until I was happy and then fixed down to the strengthening struts under the van as Reimo instructions.

I then fitted 15mm batten across the van to fix the flooring to.



I then fitted 15mm insulation between the battens.





9mm Ply board was then cut and profiled so the rails slotted through.



After fitting the other side, I then fitted a piece of black Altro flooring to finish it off. Its not all fixed down at the moment as I am making sure all cabling is in first befor the glue goes down.

Mr Scoops wrote:

Looking good Amigo

Thanks. Long way to go yet!!!

Took the van out for a spin and got the side windows re-tinted as the old stuff was starting to bubble and also got a sunroof fitted.

Decided to fit it in the second bay so it will be over the hob in the camper units.







Couldn't decide where, if any, position for the rear speakers so decided to fit them in the tailgate. Will have to upgrade the struts now as its a bit heavy!!



Also re-fitted the head lining with a bit of fabric.

Before I could start insulating the sides out, I had to remove the side door rail and get it powder coated, not that it needed doing but to change it from stainless colour to black as it was the only shiny thing left on the van.

Here it is fitted back on.



So next came the insulating.



And now back in with the Styleline panelling and a strip of LED lights around the top.

Wow, just looked back through this and its changed quite a bit since then. I'm nearly there with it so I better get a few more pics up.

Firstly, lets look at how the lights are coming on.

As the bonnet is modified and the new round headlights are in I went about making the cowlings to go around them.

First I made some moulds from the original lenses to get the correct contour for the front.











Next I had to remake the top edge of the mould to suit the new bonnet profile.



I then needed a way of offering this mould up to the lights to get the positioning of the lamps correct. I decided to get the moulds vacuum formed in clear plastic so I could offer the forming up to the lights and transfer the light positions back to the mould.





I then decided that a tapered tube around the light units would project too close to the edges of the cowling so I went for a parallel tube and proceeded to attach them to the forming with a hot glue gun to get the positions correct.







Once happy with both sides I transferred the tubes to the original moulds.
I then proceeded to fill the tubes with pattern resin to built up the bosses on the mould.
When it had set, I gave it a proof spray of undercoat to identify areas that needed sanding and filling.







I then spent time over 3 days waxing and polishing the mould ready for fibreglassing. I currently have one mould fibreglassed out curing and will be de-moulding sometime this week.

The rest of the van is also near completion and I will get those pics up shortly.

That's a lot of patience gone into building those light covers, can't wait to see them finished, along with the rest of the vans latest updated photo's.

Excellent work 'Tigger', a man with loads of talent.

Looking good Dude

Thanks guys.

Well the first fibreglass form came out of the mould in good shape although the mould had to be partially broken up to get it out. This I had expected.

So on with the second one and again not too bad a result.

Then a proof spray of undercoat and a good work over with 180 paper and filler. Next 240 then some Hi-build paint and on with the 400 and 600 grit paper.

A few coats of top coat satin black and they are ready for fitting.





Brackets made and all fitted on.

Well happy with the results. Something a little different from the norm.

Looking good fella.

Very nice - always good to see someone doing something unusual.

Thanks all.

Just sorting out my pics of the rest of the van.

Having a nightmare with photobucket so looking at other options. Any suggestions?

looks good matey, nice to see something different !

Just back from having the roof wrapped. Fantastic job by South West Tinting in Wellington.

Looking Good man!

Looking really good, just looked at the rest of the tread