Volkswagen T5 other 2006 User Manual

THE CAMPER CONVERSION MANUAL

1-1-3. A van with high mileage but lots of regular

maintenance and a full service history will generally

be more desirable than one that shows a lower

mileage but which has been knocked about and not

properly maintained.

carry out the conversion to a camper for us.
After all, Leisuredrive had converted our
previous VW Camper and six years of use
had seen nothing break, come loose or fall
off! And that’s where this book began.

There was once an advert for razors
where some smug-looking feller held up
a razor to the camera and said something
like, “I tried this razor and liked it so much,
I bought the company.” Well, I’m fortunate
enough to test drive quite a few vehicles in
the course of my work as a motoring writer
and I can honestly say, “I test drove the van
and liked it so much, I bought one!” Not as
spectacular a claim, perhaps – but at least
it’s true ...

SECTION 1. MODEL TYPES

Ninety-six models – which is right

for you?

A VW press release of 2006 posed the
above question of the T5 Transporter
– and it wasn’t even including the Caravelle
MPV range! However, it’s not as daunting
a choice as you might think and, buying
second-hand, you won’t have the detailed
choice that the new vehicle buyer enjoys.
However, there are several major categories
of Transporter available at the time of writing
and you’ll need to know which version you
want before you start looking because their
detail characteristics are quite different.

All the engines are powerful and
economical TDI engines and feature
Volkswagen’s ‘Pumpe Duese’ (PD) unit­injector technology. Other main features
include: long service and maintenance
intervals; independent suspension on all four
wheels and agile handling; superb, slick gear
change; ergonomic cab design with car-like
qualities and comfort levels.

Gross vehicle weights, at time of
launch, ranged from the T26 (2.6 tonne);
T28 (2.8 tonne); T30 (3.0 tonne) to T32
(3.2 tonne). The vehicle we chose is a T28,
to provide 200kg more carrying capacity
than the base vehicle, plus, we assumed,
more resilient suspension for a vehicle
carrying the kitchen sink around with it the
whole time but at very little extra cost.

1-1-4. The window van which has windows behind the cab but not at the very rear could be a good basis for

a conversion, but this is the Shuttle which has a sliding door on each side that makes it unsuitable.

All have:

• two wheelbases: 3m or 3.4m.

• three roof heights (only one for the

Shuttle).
VW’s designated model types are currently:

• The Transporter Panel Van.

• four gross vehicle weights.

• load compartment volumes of 5.8m3 to

3

9.3m

• seating for 3

The Transporter Kombi

• designed to carry up to 6 people in

comfort, and a sizeable load at the same
time.

• two gross vehicle weights.

• payloads of 1200kg or 1400kg.

• a range of door and window options.

• rubber flooring in load compartment.

The Transporter Window Van

• Volkswagen’s heavy duty answer to

passenger-carrying for up to nine people.

• range of seating up to nine, arranged in up

to three rows.

• a range of door and window options.

• tough rubber flooring.

• suitable base for conversions.

1-1-5. This cutaway of the Caravelle’s internal components gives a good idea of the vehicle’s structure.

14

EXTERIOR STRUCTURAL WORK

2-5-A12. Those cut lines are now connected up, across the back of the roof …

2-5-A13. … following this rib down the length of

the roof …

2-5-A14. … and across the front, just behind the

front door. Anyone carrying out this work for the

first time will need to refer to the Reimo fitting
instructions and the dimensions of the reinforcing
sections supplied, as well as noting the variations

that Barry built into this particular job as shown later

in this chapter.

2-5-A17. Barry started at the front …

2-5-A15. Barry used his drill to make a series of

holes which he then linked together by pushing

sideways carefully on the drill (if you’re not careful

the drill will break!). Note that in this instance,

where he needed to begin cutting through a double-

sided panel, a slot needed to be made in both

sections.

2-5-A18. … and cut straight across to the other

side. 2-5-A19. He cut down the length towards the back …

2-5-A16. Barry pointed out that the jigsaw blade

he used had to be long enough to cut through the

widest box section.

49