It's curtains for the old blinds

Here's a perfectly timed upgrade that we've been wanting to do for a while. The old internal window blinds have served us well but always felt a little 'temporary'. And since using the external cab blind more often, the internal ones were simply getting in the way... the solution; curtains.

We'd been aware of a curtain kit from Kiravans for quite a while but weren't in a position to justify the price. But thanks to a competition they were running we soon found ourselves with a nice voucher towards the purchase. As is usual in the land of Stone174, nothing is ever that simple - there's nothing in the Kiravans curtain range for the right hand sliding door on our twin slider... Time for a little Yorkshire ingenuity.

As we were keen to continue using the external cab blind, the kit ordered comprised of a curtain for the left hand sliding door, one for the tailgate, and another left hand sliding door kit (a right hand fixed window version would be too wide).

Pic: Kiravans

As you can see the curtains look nice and simple - they're always under tension so don't flap or move around - and the black-out option we went for certainly seems to work.

Fitting is relatively straightforward and the mounting kit is sufficient. Confidence with a drill is required! We started on the left hand sliding door first (all fine), then on to the tailgate (again, all fine with some very slight adjustment to the curve of the rail), and then on to the driver's side sliding door.

Here we simply 'flipped' the left hand version - the top rail is still the top rail but now mirrors the one at the other side, this fits fine without adjustment. Next we offered up the bottom rail - here it doesn't fit 'perfectly' at either end - the rear corner needed a tweak to fit and the front fouls against the door handle plastic cover.

At first I thought it would be case of 'out with the angle-grinder' and trim the rail... but on closer inspection (it's always wise to take a step back, have a brew, and mull things over for a bit) we decided to remove the door handle cover, trim it to the profile of the curtain rail, fit the rail, replace the cover - perfect!

Thanks Kiravans, not only for the curtains but for letting us be your competition winners!

Connected camping

With the availability of campsite wi-fi ever increasing, and better 3G and 4G coverage nationwide, it was only a matter of time before some tech made it in to the van. I've already discussed watching TV in the van quite successfully with the laptop, but sometimes that can seem quite cumbersome and a bit of a chore to setup.

So with the recent purchase of an ipad mini my mind started working on how this could be integrated in to the van with the minimum amount of fuss and remaining as descreet as possible. I'm still saving up for the popular dash conversion for ipad but in the meantime here's how it works in the back of the van - perfect for those wet weekends and lazy mornings in bed.

Here's the bracket fixed to the centre of the roof section above the head of the bed:

Nice and simple, uncomplicated and quite descreet (even moreso when I paint the screw heads black). And here's the ipad holder - note that the ipad stays in it's case for ease of use:

The holder simply slides and clips in to the bracket and can be easily operated at arms-length whilst lying in bed (as demonstrated by Mrs. Stone174 whilst in bed):

And now the flexibility of everything the ipad has to offer is available; television, films and radio, weather, news, email, facebook, an alarm clock, tide times, the list is endless...

There's loads of different types of holder out there. This one was bought on ebay for around £10. Just make sure it will hold an ipad completely upside down and not just at 90 degrees.
Here's the link to the one I went for:

Winter update

Here goes yet another post where I start by apologising for the huge gaps between posts; Winter is never the best season for getting out and about in the van or for just getting outside and doing all those little jobs and modifications that I'm wanting to do - it's been too cold.

So as we near the start of the 2015 show season I thought I'd jot down a little update whilst we all look forward to some warmer days and nights ahead.

I've had VWt Magazine chasing me again, asking if the van is ready for a feature yet. And again I've had to decline. The main reason still being that I don't feel the van is 'finished' enough yet - I'd be going against my 'no compromise' ethos by saying yes to a feature when there's still quite a few changes I'd like to make. So try and focus a little (and attempt to wrangle the savings and budgets in to shape) I've set myself a tentative deadline of Busfest 2016 to get everything done.

It sounds a long way off but I don't have the funds to do all the changes I'd like in one go - all the time I'm becoming conscious of newcomers to the T5-scene jumping in with big budget vans making all the mods I'd like to make... am I being left behind? Will my van still be show-worthy?

There's no way I'm stopping though, this is my van built the way I want, not for anyone else. Plus I'm banking on the final result being pretty unique - there's a few changes and additions in the pipeline that I don't think anyone else has tried yet.

There will be more info on some of those modifications soon, and a return to more regular blogging as the year gets going. See you out there...

More storage

As any fellow campervan'ers will know, it's all about the storage - especially us small-van'ers. They say every inch counts when it comes to hiding/storing all those little bits and bobs you seem to acquire over the years and then carry around with you.

One area of the van I felt could be improved upon is the sliding door; two large cavities that have been panelled over with no frills by Volkswagen on all but the top of the range Caravelles and Californias. Scouring the internet for good used door panels from these models and you're quickly well in to three figures - and with no guarantee of secondhand quality (and a few dubious sources) and I'm left looking elsewhere...

Here's the sliding door from inside as it has been since carpeting the van back in March 2009:

Fairly plain and boring, not living up to it's full potential, just adding to a sea of grey carpet.

Then a couple of weeks ago whilst browsing the T5 forum, I found a few other owners that had bought a new product from Kiravans that fits the brief. It's still in a pre-production test phase at the moment but this replacement panel complete with three storage compartments is going some way to maximise every useable space in the van:

It looks a little 'plain' at the moment, still in factory grey, but once trimmed along with the front door cards and refitted with blind clips to hide those standard clips it should feel much more at home. The top pocket is ideal for things like a few bungee cords or tent pegs, the middle pocket would take a few folded newspapers or magazines, the lower pocket is ideal for a full size umbrella which neatly clips in at either end.

Great service from Kiravans too; emails promptly answered, ordered Thursday afternoon and it was delivered at 9am Friday morning. Fitting takes around 10 minutes - a little longer depending on what you may have fitted to your door already.

Release the Hounds(tooth)!

After what seems like a relatively quick two weeks the van is back on the drive after it's trip to the trimmers. Our initial pre-pick up nerves soon diminished on seeing the finished results which far exceeded our expectations. As you'll know from previous posts we had given MJ a fairly tight brief - to the point that I had even photoshopped a T5 seat to explain where the fabric/leather meeting points should be (I've seen a few styles that I don't like and didn't want in my van) - I think we found the right point somewhere between 'client from hell' and 'knowing what you want'.

We also threw in a couple of last minute requests just before dropping the van off. One of which was to change the colour of all the seat plastics. Having seen a few retrims on the recent Busfest visit it was clear that good quality nappa leather meeting commercial van-grade light grey plastics wasn't going to look right. To achieve the no-compromise, factory OEM look, we had to change the colour of the plastics to the darker Caravelle-spec anthracite.

And that's quite a lot of plastic for two captain's seats:

This had obviously added to the initial one-week turnaround time, not a problem - we've waited five years for this moment! Going back to the previous posts you'll have seen my teaser as to the finish and materials chosen, a part of the brief that didn't change. Here's a few taster pics:

The front seats are pretty much perfect. Exactly the result I was hoping for - enough of a difference to make them stand out, yet not too far to look out of place - if that make sense? I'm not trying to make a 'luxury' vehicle with diamond stitching and fancy embroidery, just a quality finish that looks like something Volkswagen might have done with a bigger budget.

The rear seat trimmed to match has started the process of tying the two areas of the van together:

The bed frame might get a coat of darker paint just to help it blend in a little more. We had some fresh foam cut in the firmest grade possible (we both like a firm bed). The front edge roll makes for a really comfy seat and helps the otherwise 'square' foam look a little more rear-seat like. Another pair of headrest may also be added at a later date.

There's some exceptional attention to detail from MJ Interiors - I hardly need to say that they come highly recommended!

Another last-minute request was a pair of map pockets in the front seats:

A good shot showing the darker plastics:

A wider shot of the front seats, well worth the wait...

So that's it. Stage two will be dashboard, steering wheel, doorcards, A and B pillars, headlining, and a few other tweaks. Now to start saving up again, it won't be another five years I can assure you!

Trim Teaser Two...

Another quick visit to MJ interiors to check a sample of the material we've chosen for the centres of the seats. So here's a little indication as to how the trimming will look:

Dark grey Porsche dogtooth pattern fabric flanked by anthracite BMW Nappa leather finished with a cyan blue top stitch. A nod to the old-school without deviating from the OEM theme too much; quality materials, craftsman-quality finish, zero compromise.

And that's all I'm giving away...

Trim time teaser

At last! Time to sort the interior. I wrote in my wish list five years ago that the interior trim would be one of the last jobs we get around to - and that time has come. I won't be giving anything away just yet but will try to update the blog as regularly as possible when it starts to happen.

Because we use the van all year round it's become hard to decide when we can do without it for a couple of weeks - so we've pencilled in a date after the main VW show season has finished, mid September. Thankfully this ties in nicely with the trimmer who has a waiting list of people wanting his expertise on their projects and falls before his annual rush to get jobs finished for Ultimate Dubs; the show that many people see as the season opener and an opportunity to debut their new cars.

So who's the trimmer? After a few conversations with fellow T5 owners, much internet research, and a visit in person, we've decided to hand the van over to Michael at MJ Interiors near Shipley. Their reputation is second-to-none and they're local too (which helps us check progress if required).

The process will be a two-phase affair; front seats and rear seat first then, after saving up again, doorcards and dashboard will be trimmed to complement the seats and lessen the 'van' feeling of the standard cab - not to mention eradicating a few rattles along the way!

We had a great first visit; Michael took the time to talk through various options on leather, fabric, stitching and thread, even though both Mrs. Stone174 and I have very set-ideas on the look we're trying to achieve. Between us we made a few minor tweaks and now have the overall 'look' down on paper ready for a quotation to come through. 'No compromise' and 'less is more' are still the main themes running through the van, hopefully the end results will tie in nicely with the external look of the van and finally give us something we'd be happy to show off more than we have to date... as usual, watch this space!

Interior tweaks

With one week to go before our annual road-trip to the Volksworld Show and a day out in London, it was time to make some little upgrades that had be mulling around in my head for a while...

One was to get the leisure battery changed for a fresh one. I'd known for a while that the old one had been struggling to get back up to full capacity so a quick trip to Go Outdoors and a fresh 100aH Numax battery was bought and replaced.

Whilst the battery was out I decided to change the old 12v DC socket that sat next to the control panel for a 5v USB socket. Reason being that we only ever seem to use that socket for charging phones so instead of an adapter why not swap the socket internals - dead easy to do with the interchangeable CBE system.

Whilst on the subject of electrics you may recall we had the van in at The Campershak recently for repairs and a few tweaks - one of these adjustments was an opening hatch in the base of the clothes cupboard to give better access to the fuse box and distribution box for the CBE system. Here it is:

As usual, great attention to detail and finish by the guys at The Campershak matching the wood grain across the doors perfectly. You can just see the fusebox in the lower pic - no more 'potholing' through the rear hatch (complete with headtorch!) just to swap a fuse - now it's a breeze!

And that's it for now - we're ready for the 2014 show season. Can't wait to get to Volksworld next weekend with two nights at the Chertsey C&CC site to wind-down afterwards... see you there!

Good weather, good omens...

...and a long-overdue update.

It's Dubfreeze again! Back out of hibernation and raring to get the 2014 show season underway. I did start to question what on earth we were doing on Saturday morning; packing the van in the rain with a cold wind blowing sideways, meeting friends and driving over the M62 and down the M6 on a day when the media is telling us not to travel unless you have to... and we're going camping!

Good morning Stafford!

But the morning after the beers had washed away the memory of bad weather dawned crisp and bright. The temp gauge said 0.5˚C and the ice on the bonnet confirmed it. The inside temp was around 12˚C thanks to the Eberspächer and the roof staying down overnight.

Roof popped, kettle on.

The journey down was yet another confirmation that the recent DMF and clutch replacement had been a complete success - no more judder under load, everything operating as it should.

If you search previous posts you'll read about my love of Dubfreeze and the fact that it's not so much a 'show' as a reason to get out - and I'm so glad we (and many others) did - it's amazing what a little bit of sunshine can do for the spirit!

On another positive note, we chatted to someone about another 'upgrade'... not so much a modification, but definitely one to keep an eye out for. It won't be happening until mid-August but fingers-crossed this will be one thing that will make the van truly unique amongst it's stablemates. Sorry, I'm not giving anything away just yet...

The van will also be going back to The Camper Shak on Friday for a few interior tweaks and a repair to some damage done last year; nothing major, just a freshen up ready for camping at the Volksworld Show in March - see you there!

Preventative measures

Okay, so Winter might not be camping and show-going every weekend but it does make for a great time to sort any little issues you might be having with your van. We've got one. It's the dreaded dual mass flywheel.

Now it's not often that Stone174 gets his fingers dirty and starts talking about things under the bonnet, but there's so much forum-talk, speculation, doom and gloom about the subject, I thought I'd do a little research and put something up on here.

Dual Mass Wha...?
The dual mass flywheel (or DMF if you like) is fitted in most modern diesel and petrol engines, both passenger car and light commercial vehicles. In fact nearly all Diesel Light Commercial Vehicles built today benefit from a DMF, providing van drivers with smoother more refined vehicles.
Engine torsional vibration (TV) has increased over the years due to greater cylinder pressure and increased compression ratios. These increases have been so great that a cure had to be found for the extra vibration. The DMF absorbs all the torsional vibration and gives the added benefits of reducing noise, reducing fuel consumption and protecting the driveline from the harmful vibration and occasional injector misfire.

Worried yet - what are the symptoms?
We first noticed ours going after the van had been stood for a couple of weeks; engage first gear from cold, pull away with a bit of gas and judder, judder, judder...
Once warmed up it all goes away. Using the van daily and it doesn't happen. Leave the van for a week and it's back.
Many people say there's nothing to worry about, it's just a build up of condensation on the flywheel, perfectly normal. I'd say ours has got noticeably worse over the past 12 months.

Time to replace?
There's never a good time I suppose, but there's always a bad one. More often than not we're in the van doing something we've been looking forward to; heading to a show, a week off work etc. The last place we want to be is on the hard-shoulder and making small-talk for several hours in the back of a recovery wagon (no offence to the AA). So, combined with a 90,000 mile service and MOT, we've chosen to replace the DMF and clutch in one go.

Is there a cheap option?
In a word, no. We're not ones for scrimping on pattern-parts, this is one item that needs to be OEM.

Parts required for the 2.5 174 engine will be:
Genuine LuK 240mm Dual Mass Flywheel
Genuine SACHS SRE Organic / Sintered Clutch Disc
Genuine SACHS SRE Pressure Plate
Genuine SACHS Releaser
Flywheel and Pressure Plate Bolts 

This is an uprated direct replacement for the OE LUK Kit found on the 2.5 TDI Transporter T5 with the 6 Speed Gearbox. The Organic Clutch Disc are rated by Sachs to 390Ft/Lbs+

Parts cost is around £675. With roughly around 6 hours to fit.

What about going back to a Single Mass Flywheel?
Initially the unit cost may be lower, however in the long run damaging vibrations that were previously isolated by the DMF could affect or damage other parts of the vehicle. Failures can occur as a result of retro-fitting solid flywheels. Vibrations not eliminated by the flywheel have been known to destroy gearbox components, contribute to broken crankshafts and increase noise or resonance within the vehicle cabin to unacceptable levels.

So there you have it, not the sexiest of Christmas presents I've ever received; not quite the glamour of new alloys and airride of this time last year - but these part are just as important. The van is booked in to Aire Valley Workshop for the first Saturday in 2014 and they're keeping it for a week.

Cornwall trip & Busfest 2013

I know what you're thinking; there hasn't been a post on here for a while. So here's a long-overdue update...

There's nothing much to report on the van front other than it has been in regular use as Camper, show vehicle, bike transporter, spare room, and chill-out area. Early September saw us make our annual pilgrimage to the Southwest for some camping, surfing and general lazing about, with the return journey being interrupted by a stop at the Busfest show under the Malvern hills.

Our first stop was at our regular haunt, Trewan Hall campsite near St. Columb Major. As the week progressed, the campsite emptied leaving just us with a field to ourselves.

The weather was kind so we made our usual trips up and down the spine of Cornwall; St. Ives is one of my favourites - but it's always better when you take the park and ride train from Lelant rather than struggling to drive into town and find a parking space.

The Eden Project is always quite high on our list and one we hadn't visited in quite a while. The addition of the new aerial walkways adds a great new perspective to an already spectacular site.

Plenty of chilling out with our fellow van-campers took place. If ever there was a perfect time and location for the 'snail-like' lifestyle of carrying eveything around with you, it's Cornwall in early September when the weather can change three times in a day. One minute you're sat in the fog, the next minute you're getting ready for a spot of surfing under clear blue skies.

Perranporth sunsets are always a bit special in September.

Feeling refreshed from a few days in the southwest, it was time to head north to our next stop; the Blackmore Camping & Caravanning Club site just a mile or so down the road from Busfest at the Three Counties Showground. Being on a designated hard-standing pitch isn't quite the same as the freestyle Cornish camping, but having electric hookup was nice as the temperature had cooled.

A small selection of the awesome vans at Busfest:

Busfest was as busy as ever and there seemed to be even more of our European bus-loving cousins making the trip to the show. Loads of Germans, Dutch and Belgians in attendance - they always come over with the really cool vans that never really sold in the UK; syncro T4s and cool early bays were in abundance. The show and shine was a little thin on T5's - more than last year, and the quality/taste is getting better year on year.

This year really highlighted the need to get our interior done. Sticking with the 'no-compromise' ethos, I'd really like the dash and door cards trimmed along with the front seats and rear seat/bed. Cost-wise I fear this will have to be done in two stages; we'll get the seating done first as Mrs. Stone174 can no longer deal with making the bed up with just bare foam and an Ikea throw.

As ever, keep watching this space. I'll try and put up a few musings as to the direction I'd like the interior to take, without giving too much away! Apologies for the break between posts - but you can't blame me for being out in my van all the time!!!

Micro Mods: Window Winder Wheels

The cab area will be one of the last parts of the van to have any sort of modification done to it. Other than the footwell lights and the cab light it is pretty much untouched.

Then I saw this mod done on the T5 forum and thought I'd give it a go. At first glance I couldn't work out how the winder handles came off, but it's dead easy once you know...

Simply squeeze the lock-ring behind the handle and pull it in the opposite direction to that which the handle is pointing - simple. Then it just pulls away from the mechanism.

Once off I simply chopped the back of the small wheel section to remove the spinning part. Then using a small cabinet connecting bolt and some loctite on the thread, add the skateboard wheel of your choice:

Before and after

Then just replace the handle in the opposite of removal. It's probably wise when choosing your skateboard wheel to keep the diameter small, a larger wheel might put too much stress on the handle - Stone174 accepts no responsibility for your own breakages!

And here's the finished thing, for now. The beauty of this mod is being able to change the wheels for something else at a later date:

  

Front splitter wanted...

I'm currently on the look out for a slim-profiled front splitter to sit under the Sportline chin.

Must not be the popular Seat Leon Cupra R splitter that many others have fitted (too rounded). So far, I've looked at Mk2 and Mk3 Golf, Renault Espace, various Vauxhall splitters and plenty of eBay-specials!

The look I'm trying to achieve:

Just enough to visually lower the front a little further. All ideas and recommendations will be gratefully received - I'm quite happy to break out the Dremel and junior-hacksaw if required.

Micro Mods - an update

Finally it's warm enough to do something outside without losing the feeling in your finger ends. Ideal for changing the bulbs in the new cab light:

For the main centre light I've used a 3x SMD Festoon C5W 44mm unit. And for the two reading lights I've used 4x SMD W5W Sidelights.

Light output is massively improved. Nice and white, very bright, and an inexpensive upgrade.

Prosport Problems

Clonking, honking, creaking, choppy, lurching and generally a bit vague?

Wonder what that could've been...

Airride - time for some pics

The novelty is far from wearing-off. Parking up becomes funny wherever you go; airing-out in front of unsuspecting passers-by with a loud 'Pttsssssshhhhh' seems to stop people in their tracks.

Here's a few 'aired-out' (that's all four bags devoid of any air pressure) pics to whet your appetite - click any pic for a larger version:

So far, the ilevel app has been faultless; being able to pre-set ride-heights and have the trim-mode set to permanently monitor ride-height is awesome.

Here's the van in setting 3 - 90% full - Ideal for getting on to campsites, rough terrain etc. Ride quality is good at this height if a little firm.

Here's another pic with the van set to pre-set 2 - daily driving - looks cool and driveable. Ride quality is fine at this height; similar to factory.

And between the presets we have any infinite variation of height and rake, perfect for leveling up at a campsite:

Nose up, back down - good for those sloping Welsh campsites.

Nose down, back up - for that hot-rod rake!

Being able to control all four corners independently means side-to-side slopes can also be dealt with. Here's driver's side front and rear up and passenger side front and rear down:

Camping whilst there's very little air in the bags also gives a firmer base - no longer when turning over in the night does it feel like the whole van is moving. Dubfreeze was a great night's sleep.

You'll notice there's no pics of the eLevel touch pad on the dash yet. I'm still undecided as to how I'm going to mount it. I'm tempted to remove one of the heater outlets next to the head-unit and flush-mount it there. For the time being it will sit loose on top of the dash.

So that's the airride in a nutshell. If you have any questions (just not 'how much?') feel free to get in touch using the ask Stone174 link at the top of the blog.

Stone174 airride specs:
Airrex front bagover struts and rear bags/dampers.
Viair twin 480 air compressors
Accuair 5 gallon air tank
Accuair VU4 solenoid valve unit
Accuair eLevel management
Accuair iLevel iphone integration module

Fitting/setup by iKustoms