Exterior:

The entire exterior was stripped down and windows removed for a full paint job in Audi Ibis White.  Ibis white is a beautiful bright white that looks incredible in the sun and it felt like the right choice keeping the color in the VW family.  The rockers were shot with an OEM rocker guard (keeps chips at bay but looks much better and more OEM than the bedliner trend that is so prevalent right now).  The top was refinished and painted at the same.  All windows were all tinted in ceramic (heat blocking) high end film (formula one and 3m crystalline).  The front windshield has no noticeable tint but blocks much of the heat, the front doors at 40%, and all rear windows at 20%.  All windows were reinstalled with German/OEM window seals which fit better and last much longer than the aftermarket version and windshield was replaced at the same time.  Then every seal was replaced:  front doors, sliding door, rear hatch, and pop top.  Every bit of exterior trim was also replaced (gutter, etc).   Antenna and other exterior hardware and lenses showing wear were replaced.  Front window scrapers and trim was replaced and the front luggage rack was completely refurbished with new trim, seals, screens and hardware.  Camper hook up boxes were replaced with new from Gowesty.  Upgraded truck mirrors were installed from Gowesty.

The canvas pop top was replaced with an upgraded Sunbrella top from North Westy with fine screens that keep out even the smallest bugs and zip out windows, all skylight hardware was replaced and the skylight was replaced with a dual pane version that is much better insulated.  The flocking was also professionally cleaned, and a poptop shock kit was installed for assist when lifting the top.

Rocky Mountain Westy provided the front and rear Twin Peaks Bumpers with stainless steel hardware.  The rear has an integrated hitch and a swing away spare tire carrier and rear folding cargo shelf were added along with recovery points. The front was outfitted with the deluxe grill guard. Cost of the bumpers and swingouts alone was $3800!

Fender flares front and rear were sourced from Terrawagen and Rallyarmor mud flaps were installed.

South African upper and lower front grilles were installed along with Holley Retrobright LED lights (inner and outer) along with a relay kit for each and were wired with the optional quad low/quad high harness.

Door handles were replaced to be keyed alike. 

An ARB awning was installed using Rocky Mountain Westy mounting brackets.

All exterior lights were replaced with LED.

Suspension & Brakes:

Every bushing in the suspension front and rear was replaced with Powerflex polyurethane from T3 technique, all replaceable hardware, bolts, nuts and washers was done at the same time:  This includes Powerflex front radius arm bushings, Powerflex upper control arm bushings & Powerflex trailing arm bushings.  All were lubricated with ‘bushing snot’ a tenacious anti-squeak bushing lube from T3 Technique.

Springs were replaced with Steve Schwenk springs front and rear (firm and controlled but comfortable springs).

Shocks were replaced with Bilstein HD front and rear.

Power steering was added with the Ultimate Engineering Electric Power Steering kit, all rag joints were replaced, a steering rack reinforcement kit was added from T3 Technique, and the gearbox mount bushing and steering rack bushings were replaced with Powerflex bushings.  This is a vastly superior system to the original OEM which is plagued by leaks, noise, long lines front to rear, and an assist that isn’t always adequate.

Upgraded front disc brakes were installed from Smallcar and upgraded rear disc brakes were installed from Burley Motorsports.  All bearings, seals, etc were replaced and packed with synthetic grease.  Ball joints upper and lower were replaced with OEM TRW (lower) and T3 Technique HD (upper).

(5) Mercedes CLK forged lightweight aluminum wheels were purchased and all were professionally stripped and powdercoated in a dark bronze along with T3 Technique center caps and Wolfsburg logos.   They were installed using T3 Technique studs and nuts.  Toyo Open Country ATII tires were installed.

The HD 25mm sway bar (anti roll bar) and endlinks from T3 Technique were installed.

New tie rod ends from Van Café

Powertrain:

The engine is from a 1991 Subaru EJ22, one of the best Subaru motors ever made (non-interference design).  It was installed at 113,505 chassis/vanagon miles with 68,000 miles on it. Current mileage on the van is 121,299 so the motor has just shy of 76,000 miles on it at the time of writing this ad.  To my knowledge this is one of only two CA legal conversion kits, the other being the VW 1.8T. 

Prior to this sale I had Kennedy verify that the conversion is compliant with the executive order and they sent the updated CARB placard which is pictured in the photos.  I can provide the email with them to any interested buyer. 

The following components were used:

Kennedy Engineering conversion kit (CA legal)

Westy Ventures TDI starter adapter with Bosch TDI starter and Jay Brown vanagon hard start relay kit

Vanagon hard start relay kit

RMW VSS

RMW ‘the Tank’ aluminum coolant expansion tank

RMW ‘stealth’ muffler kit (easily swappable back to Kennedy muffler).  Note:  I have the Kennedy muffler still and my understanding is you would need to have it installed to pass the CA inspection.

RMW Subaru conversion shortened oil pan

RMW throttle cable

Tom Shiels EJ22 thermostat housing, OEM Subaru thermostat

OEM spark plugs, wires

Napa alternator

Fatmat sound/heat liner in engine bay cover

Gowesty alternator and battery cable wiring upgrade kit

Autometer oil pressure and water temp gauge with T3 Technique gauge pod

New complete cooling system: Van Café stainless steel coolant pipe kit, radiator, new hoses front to back (radiator and heater).  Radiator fan was put on a relay kit and additional grounds were added.

New complete fuel system: New tank with later 12mm output line, Bosch pump, sending unit, filter, Marco Mansi prefilter prior to pump, lines, roll over valves, grommets, all lines to vapor tanks also replaced.  Heat shielding added to fuel lines in engine bay and a vented stone shield was added below the pump and prefilter.

Blazecut automatic fire suppression system added.

An Odyssey AGM battery was installed with a CTEK AGM compatible battery charger.

Shifter linkage rebuilt front to rear, T3 Technique easy shift kit, and shifter extension.

Swepco 202 Moly 75W90 upgraded transaxle gear oil (recommended by one of the most respected Vanagon transaxle builders).

All four CV joints were replaced along with boots.

All wiring diagrams were retained and I have a spare EJ22 ECU in case of failure.

Electrical / Camping:

A Propex HS2000 heater was installed under the fridge to maximize storage space using the install kit from Rocky Mountain Westy.  Ducting was upgraded to the acoustic for quieter operation and the thermostat was upgraded to the digital unit.

The original propane tank was replaced with a slightly oversized 3.3G new tank and regulator ($900).

A Vitrifrigo 12v compressor fridge was installed using the install kit from Rocky Mountain Westy and the front laminate was color matched to the OEM interior laminate.

An upgraded table leg and clamp kit was installed from Vanagonlife allowing vertical extension of the table.

Gauge cluster was upgraded using the printed circuit board replacement from Gowesty

Faucet was upgraded to a Shurflo

Upgraded interior lighting including a spice rack kit, door open kit, night vision kit, and a dimmable touch light bar for the cooking area was installed.

Polk audio speakers were installed front and rear, a JVC reduced depth head unit was installed, and a Gowesty switchable toggle switch was installed which allows selection of the house battery or starting battery.

Stove valves were rebuilt

Upgraded rubber mats were installed in the rear passenger area and in the rear cargo area.

Interior:

Headliner and door panels were replaced with custom made birch panels with stainless hardware.

Cork flooring was installed in the rear passenger area (cool in the summer and warm in the winter).

Front seats were replaced with more comfortable folding Town and Country seats using Smallcar brackets.  

The steering wheel was upgraded to a Eurovan steering wheel

Screens were replaced with upgraded Gowesty units

A locking center console was installed with cubby and cupholder upgrades from Gowesty

The speedometer was rebuilt (mileage kept) and a Gowesty audible coolant temp alarm kit was installed. 

Autometer oil pressure and engine temp gauges were installed with gauge pods from T3 Technique. 

A digital voltmeter was installed from Blue Sea

Every roller and bushing in the sliding door was replaced and some upgraded to quiet rolling Delrin (when available).  Door beading was replaced.

A bunk step was installed from Rocky Mountain Westy.

Cork floors were installed in the rear passenger area.

A memory foam topper was purchased from Rocky Mountain Westy.

A lockable sliding storage drawer was installed under the passenger seat from RMW.

Grab handles replaced from Gowesty.

Leather curtain ties were sourced from Gowesty.

A Vogel Werks ‘Vangaroo’ rear storage panel for the hatch was added for additional storage.

A 3m Thinsulate Acoustic Thermal blanket was added above the rear engine compartment and below the rear seat.  Additional Butyl acoustic and thermal insulation was added to the rear engine panel and in the rear seat storage area.  Fatmat heat and sound hood liner was added to the rear hatch cover. Butyl acoustic insulation was added to the front doors, sliding door, and rear hatch.

Safety:

Front seatbelts were replaced from Gowesty and rear three point seatbelts were installed with the optional finishing trim kit.

Rear headrests were installed using OEM components from Frank Condelli

A Gowesty rear car seat tether kit was installed.

A Vantop digital rear view mirror and front dash cam were installed.

The upper bunk was outfitted with an Obeco safety net (to keep kids from rolling out of bed).

An upgraded Hella supertone horn was installed with a relay kit.

Air Conditioning:

An upgraded Smallcar air conditioning system was installed.

New compressor and tensioner from Subaru.

New lines and fittings front to rear.

Oversized 16x24 condenser for increased performance.

Illuminated LED AC controls.

House Battery System:

A Battleborn 100ah battery was installed with a Victron Orion Bluetooth DC/DC converter, dual Blue Sea battery cut off switches, a Victron Bluetooth Bluesmart battery charger and Victron SmartShunt Bluetooth battery monitor. 

A Blue Sea auxiliary fuse panel was installed for the furnace, kitchen, fridge, radio, interior lights and charging outlets.  All wiring was sourced from Lawrence Marine Products using appropriately sized tinned copper wiring, fused, properly crimped, heat shrunk, and labeled with heat shrink labeling. 

Maintenance:

Oil changed regularly with Pennzoil Ultimate Platinum 5x30 full synthetic in cold weather and Shell Rotella full synthetic in hot weather.  Upgraded Fuji oil filters were used.

Subaru coolant only.

ATE brake fluid changed regularly.

4 wheel alignment done regularly.

Fresh water system sanitized twice a year with Purogene.

Swepco 202 Moly 75W90 upgraded transaxle gear oil (recommended by one of the most respected Vanagon transaxle builders).