Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics

1
If anyone is wondering what to do on a spare afternoon here's how to put a raised fixed roof in a syncro. Interesting pictures and insight into the roof structure but  I do hope this bloke never worked for the company that put in my pop-top. 
Cheers
Roger

--- On Tue, 26/10/10, jmv <jmvbike@gmail.com> wrote:

From: jmv <jmvbike@gmail.com>
Subject: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: Adventurewagen@yahoogroups.com
Received: Tuesday, 26 October, 2010, 9:03 AM

 
 

Sent: Monday, October 25, 2010 8:01 AM
To: jmv
Subject: Re: Harness arrived but parts are missing.

See ####

David Marshall
VW Adventure Driver and BMW Adventure Rider

http://www.hasenwerk.ca

On Sun, October 24, 2010 21:02, jmv wrote:
> Hey Dave,
>
> I have been in full Vanagon mode since we emailed last.
>
> I just completed the Adventurewagen roof install onto my hardtop Syncro
> yesterday.
>
> I'm pretty happy how it came out.
>
> Although it kinda looks silly for now with a brown & tan AW roof on a gray
> with silver trim Syncro. 

#### my former syncro camper had a high root - it was the cat's meow!!!

> Well?,
>
> I have another piece of wiring harness.
>
> Basically the guy told me he had two of the harness + the complete wiring
> loom.
>
> So being tired and not that well prepared I shipped out the big box
> thinking it was all there.
>
> I can send out the other piece of wiring tomorrow.
>
> Umm glow plugs?
>
> What glow plugs?
>
> This engine has no visable glow plugs. 
>
> I was going to fog the engine for storage and spray in through the glow
> plug holes like I did on the 1.9 PD BEW TDI..........
>
> But to my surprise there are no glow plugs......or glow plug holes for
> that matter on the outside of the cylinder head.
>
> It appears that with the 16v head the glow plugs must be under the valve
> cover? Although I haven't removed
> the Valve cover again after my initial inspection of the cam & rollers 7
> or 8? months ago?
>
> So basically I don't think there is a glow plug harness like with a 1.9
> PD?
>
> The engine & one of the ECU's came out of a 2005 German Market Golf
> GTI-Diesel
> I understand the engine is also used in some Golf Plus cars for 2005
> &2006?
>
> The huge wiring loom with fuse block, the other ecu,dash cluster
> pod,ignition switch & key all came out of a UK Junkyard.
>
> I read some factory VW tech info on the engine & am kind of happy to find
> out that the BKD TDI engine is Basically the same exact
> engine as a 2010 2.0 TDI Common Rail engine except with PD injecton/fuel
> system instead of CR. 

#### Well, there is glow plugs for this engine.  The wife has a 2009 Jetta TDI so I can check that over to see how the glow plug connector looks - we are however still missing that half of the engine harness...

> Also the engine is EDC 16 so I understand this helps with the tuning
> options? (just read that on the TDI forum) 

#### Yes, it is an EDC 16, the CR is an EDC 17 - are you wanting to get some tuning done to this engine?  

#### As no work order was found I will recap the work that needs to be done so that we are all on the same page:

- Convert the supplied wiring harness for use in a Vanagon
- Remove IMMO so that instrument cluster is not needed
- OBD Connector, accelerator connector present at the front of the van
- K29 and K83 LED wires for the vanagon istrument cluster (not all euro ECUs have this)
- Brake connection for the master cylinder
- Cruise Control - YES or NO?
- Chip Tuning - YES or NO?

So the section of the harness that is missing contains the plug that control the EGR / Turbo VNT and Butter Fly Valve for the egine.  I also need the bit the plugs into the glow plug system on the engine to the harness that is at the fuse panel.


 
> Anyway,
>
> Thanks
>
> Jeff
>
>
>
>
>
>
>
>
>
From: David Marshall
> Sent: Sunday, October 24, 2010 5:00 PM
> To: jmv
> Subject: Harness arrived but parts are missing.
>
>
> Hi Jeff,
> I opened up the box of wires here and I hate to say it but 1/2 of the
> engine harness is missing. :-(
>
> You may have noticed that the ECUs have two plugs. I have the section of
> harness that plugs into the large plug but the smaller plug and related
> items attached to that harness along with the glow plug rail is missing.
>
> Also, what is the exact vehicle this came out of?
>
>
> David Marshall
> VW Adventure Driver and BMW Adventure Rider
>
> http://www.hasenwerk.ca
>

 
2
On Oct 26, 2010, at 5:58 AM, Roger Bell <bellrmit@yahoo.com.au> wrote:

If anyone is wondering what to do on a spare afternoon here's how to put a raised fixed roof in a syncro. Interesting pictures and insight into the roof structure but  I do hope this bloke never worked for the company that put in my pop-top. 
Cheers
Roger


Roger,

The 'high roof' in question is called an 'Adventurewagen'. It was originally manufactured in Ft. Bragg, California by a fellow called Ed Anderson. Besides the crude looking roof cuts and the thought of the pitfalls of removing one of the roof ribs, it is one of the best hightops I have ever seen installed on T3. It is surprisingly rigid when properly bonded to the steel roof despite the aforementioned removal of the roof rib just aft of the sliding door. The interior edges ate trimmed in Koa or Oak woods. 

Of the relatively available roof conversions in the US, this is second only to a genuine Westfalia pop-top. Even Jimmy Buffet  of Margaritaville fame commissioned the build of a Syncro camper with this roof (He has since moved on to a 4wd Ford with the same roof.) 

Unfortunately, the Adventurewagen is no longer in production. The only solution, should one wish to install one on a pedestrian Syncro, is by acquiring an older AW camper. Yours truly has done this six times. The original molds are somewhat available for sale. Ed gave them away some years ago. A fellow called Robert H., also in California, took custody of one set of inner and outer molds (This is a dual-shell roof.) with some assistance from the Vanagon community. He invested more time and money on the molds and made an attempt to sell new tops. Sadly, pricing them at about US$4500 each was not a commercial success. His main competition are used AW tops which can be had complete with a broken down 2wd T3 attached to the bottom ;-) for $300-$2000. Heck, I once acquired an air-cooled AW with 85 miles on the engine for about $350. That's not a typo. 

Anyway, I had/have an opportunity to rescue the molds and will likely do so just to keep them out of the landfill. It is doubtful that I will ever get involved with manufacturing the roofs myself. The hope is that some company can manage to pull tops for much less than the $4500 that Robert was asking. There are companies here who are able to make roofs for 1/3 that price. Their roof is poorly designed and unattractive. Giving them access to the AW molds might just be the best marriage in    my little corner of the T3 world.


Regards,


BenT
3
Ben, we have a phrase in Australia to describe those nibbler cuts, "rough as hessian undies"! Greg E
P.S. you do know what undies are don't you?

--- On Tue, 26/10/10, Roger Bell <bellrmit@yahoo.com.au> wrote:

From: Roger Bell <bellrmit@yahoo.com.au>
Subject: [Syncro_T3_Australia] Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: "Syncro Aust Group" <syncro_t3_australia@yahoogroups.com>
Received: Tuesday, 26 October, 2010, 11:58 PM

If anyone is wondering what to do on a spare afternoon here's how to put a raised fixed roof in a syncro. Interesting pictures and insight into the roof structure but  I do hope this bloke never worked for the company that put in my pop-top. 
Cheers
Roger

--- On Tue, 26/10/10, jmv <jmvbike@gmail.com> wrote:

From: jmv <jmvbike@gmail.com>
Subject: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: Adventurewagen@yahoogroups.com
Received: Tuesday, 26 October, 2010, 9:03 AM

 
 

Sent: Monday, October 25, 2010 8:01 AM
To: jmv
Subject: Re: Harness arrived but parts are missing.

See ####

David Marshall
VW Adventure Driver and BMW Adventure Rider

http://www.hasenwerk.ca

On Sun, October 24, 2010 21:02, jmv wrote:
> Hey Dave,
>
> I have been in full Vanagon mode since we emailed last.
>
> I just completed the Adventurewagen roof install onto my hardtop Syncro
> yesterday.
>
> I'm pretty happy how it came out.
>
> Although it kinda looks silly for now with a brown & tan AW roof on a gray
> with silver trim Syncro. 

#### my former syncro camper had a high root - it was the cat's meow!!!

> Well?,
>
> I have another piece of wiring harness.
>
> Basically the guy told me he had two of the harness + the complete wiring
> loom.
>
> So being tired and not that well prepared I shipped out the big box
> thinking it was all there.
>
> I can send out the other piece of wiring tomorrow.
>
> Umm glow plugs?
>
> What glow plugs?
>
> This engine has no visable glow plugs. 
>
> I was going to fog the engine for storage and spray in through the glow
> plug holes like I did on the 1.9 PD BEW TDI..........
>
> But to my surprise there are no glow plugs......or glow plug holes for
> that matter on the outside of the cylinder head.
>
> It appears that with the 16v head the glow plugs must be under the valve
> cover? Although I haven't removed
> the Valve cover again after my initial inspection of the cam & rollers 7
> or 8? months ago?
>
> So basically I don't think there is a glow plug harness like with a 1.9
> PD?
>
> The engine & one of the ECU's came out of a 2005 German Market Golf
> GTI-Diesel
> I understand the engine is also used in some Golf Plus cars for 2005
> &2006?
>
> The huge wiring loom with fuse block, the other ecu,dash cluster
> pod,ignition switch & key all came out of a UK Junkyard.
>
> I read some factory VW tech info on the engine & am kind of happy to find
> out that the BKD TDI engine is Basically the same exact
> engine as a 2010 2.0 TDI Common Rail engine except with PD injecton/fuel
> system instead of CR. 

#### Well, there is glow plugs for this engine.  The wife has a 2009 Jetta TDI so I can check that over to see how the glow plug connector looks - we are however still missing that half of the engine harness...

> Also the engine is EDC 16 so I understand this helps with the tuning
> options? (just read that on the TDI forum) 

#### Yes, it is an EDC 16, the CR is an EDC 17 - are you wanting to get some tuning done to this engine?  

#### As no work order was found I will recap the work that needs to be done so that we are all on the same page:

- Convert the supplied wiring harness for use in a Vanagon
- Remove IMMO so that instrument cluster is not needed
- OBD Connector, accelerator connector present at the front of the van
- K29 and K83 LED wires for the vanagon istrument cluster (not all euro ECUs have this)
- Brake connection for the master cylinder
- Cruise Control - YES or NO?
- Chip Tuning - YES or NO?

So the section of the harness that is missing contains the plug that control the EGR / Turbo VNT and Butter Fly Valve for the egine.  I also need the bit the plugs into the glow plug system on the engine to the harness that is at the fuse panel.


 
> Anyway,
>
> Thanks
>
> Jeff
>
>
>
>
>
>
>
>
>
From: David Marshall
> Sent: Sunday, October 24, 2010 5:00 PM
> To: jmv
> Subject: Harness arrived but parts are missing.
>
>
> Hi Jeff,
> I opened up the box of wires here and I hate to say it but 1/2 of the
> engine harness is missing. :-(
>
> You may have noticed that the ECUs have two plugs. I have the section of
> harness that plugs into the large plug but the smaller plug and related
> items attached to that harness along with the glow plug rail is missing.
>
> Also, what is the exact vehicle this came out of?
>
>
> David Marshall
> VW Adventure Driver and BMW Adventure Rider
>
> http://www.hasenwerk.ca
>

 

 
4
On Oct 26, 2010, at 5:00 PM, greg esposito <gregespo73@yahoo.com> wrote:

Ben, we have a phrase in Australia to describe those nibbler cuts, "rough as hessian undies"! Greg E
P.S. you do know what undies are don't you?



No point in getting your panties in a bunch, Greg. I don't know what undies are. I just assumed everyone went "commando". ;-) as they say around here.

I don't think those are the final cuts before he laid the roof back down. If they were, the AW kit has the feature of hiding a multitude of metal cutting sins. I feel a little guilty because the fellow who posted those pics asked me for advise on installing that roof. Through miscommunication, mostly on my part, the information never got back to the guy. He braved the project on his own. Here's hoping he cleaned up those cuts before gluing and screwing the roof on.


Cheers,

BenT
5
Yeh I hope he did clean up those cuts otherwise if he nods off in the top bunk he will wake up looking as though he slept with edward scissor hands.
--- On Wed, 27/10/10, BenT Syncro <syncro@gmail.com> wrote:

From: BenT Syncro <syncro@gmail.com>
Subject: Re: [Syncro_T3_Australia] Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: "Syncro_T3_Australia@yahoogroups.com" <Syncro_T3_Australia@yahoogroups.com>
Received: Wednesday, 27 October, 2010, 11:24 AM

 
On Oct 26, 2010, at 5:00 PM, greg esposito <gregespo73@yahoo.com> wrote:

Ben, we have a phrase in Australia to describe those nibbler cuts, "rough as hessian undies"! Greg E
P.S. you do know what undies are don't you?



No point in getting your panties in a bunch, Greg. I don't know what undies are. I just assumed everyone went "commando". ;-) as they say around here.

I don't think those are the final cuts before he laid the roof back down. If they were, the AW kit has the feature of hiding a multitude of metal cutting sins. I feel a little guilty because the fellow who posted those pics asked me for advise on installing that roof. Through miscommunication, mostly on my part, the information never got back to the guy. He braved the project on his own. Here's hoping he cleaned up those cuts before gluing and screwing the roof on.


Cheers,

BenT

 
6
Roger

I prefer the more ironical version of 'as smooth as hessian undies'.

On 27 October 2010 11:00, greg esposito <gregespo73@yahoo.com> wrote:
Ben, we have a phrase in Australia to describe those nibbler cuts, "rough as hessian undies"! Greg E
P.S. you do know what undies are don't you?

--- On Tue, 26/10/10, Roger Bell <bellrmit@yahoo.com.au> wrote:

From: Roger Bell <bellrmit@yahoo.com.au>
Subject: [Syncro_T3_Australia] Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: "Syncro Aust Group" <syncro_t3_australia@yahoogroups.com>
Received: Tuesday, 26 October, 2010, 11:58 PM


If anyone is wondering what to do on a spare afternoon here's how to put a raised fixed roof in a syncro. Interesting pictures and insight into the roof structure but I do hope this bloke never worked for the company that put in my pop-top.
Cheers
Roger

--- On Tue, 26/10/10, jmv <jmvbike@gmail.com> wrote:

From: jmv <jmvbike@gmail.com>
Subject: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: Adventurewagen@yahoogroups.com
Received: Tuesday, 26 October, 2010, 9:03 AM

Sent: Monday, October 25, 2010 8:01 AM
To: jmv
Subject: Re: Harness arrived but parts are missing.

See ####

David Marshall
VW Adventure Driver and BMW Adventure Rider

http://www.hasenwerk.ca

On Sun, October 24, 2010 21:02, jmv wrote:
> Hey Dave,
>
> I have been in full Vanagon mode since we emailed last.
>
> I just completed the Adventurewagen roof install onto my hardtop Syncro
> yesterday.
>
> I'm pretty happy how it came out.
>
> Although it kinda looks silly for now with a brown & tan AW roof on a gray
> with silver trim Syncro.

#### my former syncro camper had a high root - it was the cat's meow!!!

> Well?,
>
> I have another piece of wiring harness.
>
> Basically the guy told me he had two of the harness + the complete wiring
> loom.
>
> So being tired and not that well prepared I shipped out the big box
> thinking it was all there.
>
> I can send out the other piece of wiring tomorrow.
>
> Umm glow plugs?
>
> What glow plugs?
>
> This engine has no visable glow plugs.
>
> I was going to fog the engine for storage and spray in through the glow
> plug holes like I did on the 1.9 PD BEW TDI..........
>
> But to my surprise there are no glow plugs......or glow plug holes for
> that matter on the outside of the cylinder head.
>
> It appears that with the 16v head the glow plugs must be under the valve
> cover? Although I haven't removed
> the Valve cover again after my initial inspection of the cam & rollers 7
> or 8? months ago?
>
> So basically I don't think there is a glow plug harness like with a 1.9
> PD?
>
> The engine & one of the ECU's came out of a 2005 German Market Golf
> GTI-Diesel
> I understand the engine is also used in some Golf Plus cars for 2005
> &2006?
>
> The huge wiring loom with fuse block, the other ecu,dash cluster
> pod,ignition switch & key all came out of a UK Junkyard.
>
> I read some factory VW tech info on the engine & am kind of happy to find
> out that the BKD TDI engine is Basically the same exact
> engine as a 2010 2.0 TDI Common Rail engine except with PD injecton/fuel
> system instead of CR.

#### Well, there is glow plugs for this engine. The wife has a 2009 Jetta TDI so I can check that over to see how the glow plug connector looks - we are however still missing that half of the engine harness...

> Also the engine is EDC 16 so I understand this helps with the tuning
> options? (just read that on the TDI forum)

#### Yes, it is an EDC 16, the CR is an EDC 17 - are you wanting to get some tuning done to this engine?

#### As no work order was found I will recap the work that needs to be done so that we are all on the same page:

- Convert the supplied wiring harness for use in a Vanagon
- Remove IMMO so that instrument cluster is not needed
- OBD Connector, accelerator connector present at the front of the van
- K29 and K83 LED wires for the vanagon istrument cluster (not all euro ECUs have this)
- Brake connection for the master cylinder
- Cruise Control - YES or NO?
- Chip Tuning - YES or NO?

So the section of the harness that is missing contains the plug that control the EGR / Turbo VNT and Butter Fly Valve for the egine. I also need the bit the plugs into the glow plug system on the engine to the harness that is at the fuse panel.



> Anyway,
>
> Thanks
>
> Jeff
>
>
>
>
>
>
>
>
>
From: David Marshall
> Sent: Sunday, October 24, 2010 5:00 PM
> To: jmv
> Subject: Harness arrived but parts are missing.
>
>
> Hi Jeff,
> I opened up the box of wires here and I hate to say it but 1/2 of the
> engine harness is missing. :-(
>
> You may have noticed that the ECUs have two plugs. I have the section of
> harness that plugs into the large plug but the smaller plug and related
> items attached to that harness along with the glow plug rail is missing.
>
> Also, what is the exact vehicle this came out of?
>
>
> David Marshall
> VW Adventure Driver and BMW Adventure Rider
>
> http://www.hasenwerk.ca
>





--
Regards

Michael

Michael Rayner East Light Photography
PO Box 144
MALLACOOTA VIC 3892

MOB: 0409 241 672
BUS: 0351169401
A/H: (03)5158 0346

Web: www.michaelraynerphotography.com.au
Email: michaelrayner@exemail.com.au


7

On Oct 26, 2010, at 5:43 PM, greg esposito <gregespo73@yahoo.com> wrote:
Yeh I hope he did clean up those cuts otherwise if he nods off in the top bunk he will wake up looking as though he slept with edward scissor hands.




Gee, I didn't think Australians were so fragile. What's a little rough edge among friends?


BenT
8
re
the AW kit has the feature of hiding a multitude of metal cutting sins."
 
I have a vanagon roof from which an AW top was removed.
 
the cutting of the roof is somewhat 'casual' let's say.
looks like back yard work..
you know .... two six packs to get the roof cutting done.
 
 
----- Original Message -----
Sent: Tuesday, October 26, 2010 5:24 PM
Subject: Re: [Syncro_T3_Australia] Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics

 

On Oct 26, 2010, at 5:00 PM, greg esposito <gregespo73@yahoo.com> wrote:

Ben, we have a phrase in Australia to describe those nibbler cuts, "rough as hessian undies"! Greg E
P.S. you do know what undies are don't you?



No point in getting your panties in a bunch, Greg. I don't know what undies are. I just assumed everyone went "commando". ;-) as they say around here.

I don't think those are the final cuts before he laid the roof back down. If they were, the AW kit has the feature of hiding a multitude of metal cutting sins. I feel a little guilty because the fellow who posted those pics asked me for advise on installing that roof. Through miscommunication, mostly on my part, the information never got back to the guy. He braved the project on his own. Here's hoping he cleaned up those cuts before gluing and screwing the roof on.


Cheers,

BenT

9
Thanks Ben - you (along with a few of our blokes) are  like personal Wikipedias on T3 Syncro matters.I suppose the availability of medium and high roof factory versions of the latest T5 further erode the value of your moulds except for those in on the secret that there is nothing quite like a T3.
Thanks for sharing your knowledge.
Roger
 
--- On Wed, 27/10/10, BenT Syncro <syncro@gmail.com> wrote:

From: BenT Syncro <syncro@gmail.com>
Subject: Re: [Syncro_T3_Australia] Fw: [Adventurewagen] AW ROOF TRANSPLANT Swap Pics
To: "Syncro_T3_Australia@yahoogroups.com" <Syncro_T3_Australia@yahoogroups.com>
Received: Wednesday, 27 October, 2010, 1:51 AM

 
On Oct 26, 2010, at 5:58 AM, Roger Bell <bellrmit@yahoo.com.au> wrote:

If anyone is wondering what to do on a spare afternoon here's how to put a raised fixed roof in a syncro. Interesting pictures and insight into the roof structure but  I do hope this bloke never worked for the company that put in my pop-top. 
Cheers
Roger


Roger,

The 'high roof' in question is called an 'Adventurewagen'. It was originally manufactured in Ft. Bragg, California by a fellow called Ed Anderson. Besides the crude looking roof cuts and the thought of the pitfalls of removing one of the roof ribs, it is one of the best hightops I have ever seen installed on T3. It is surprisingly rigid when properly bonded to the steel roof despite the aforementioned removal of the roof rib just aft of the sliding door. The interior edges ate trimmed in Koa or Oak woods. 

Of the relatively available roof conversions in the US, this is second only to a genuine Westfalia pop-top. Even Jimmy Buffet  of Margaritaville fame commissioned the build of a Syncro camper with this roof (He has since moved on to a 4wd Ford with the same roof.) 

Unfortunately, the Adventurewagen is no longer in production. The only solution, should one wish to install one on a pedestrian Syncro, is by acquiring an older AW camper. Yours truly has done this six times. The original molds are somewhat available for sale. Ed gave them away some years ago. A fellow called Robert H., also in California, took custody of one set of inner and outer molds (This is a dual-shell roof.) with some assistance from the Vanagon community. He invested more time and money on the molds and made an attempt to sell new tops. Sadly, pricing them at about US$4500 each was not a commercial success. His main competition are used AW tops which can be had complete with a broken down 2wd T3 attached to the bottom ;-) for $300-$2000. Heck, I once acquired an air-cooled AW with 85 miles on the engine for about $350. That's not a typo. 

Anyway, I had/have an opportunity to rescue the molds and will likely do so just to keep them out of the landfill. It is doubtful that I will ever get involved with manufacturing the roofs myself. The hope is that some company can manage to pull tops for much less than the $4500 that Robert was asking. There are companies here who are able to make roofs for 1/3 that price. Their roof is poorly designed and unattractive. Giving them access to the AW molds might just be the best marriage in    my little corner of the T3 world.


Regards,


BenT