Ex-BG Maxi Micro-Camper/Daily

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sssingletrack
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Engine size/power: 1.6 CR TDI (102bhp)

Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

We picked up our ex-BG caddy with a partial camper conversion at the weekend, and we have started work to finish it off and do the job properly.

To start with some images of the exterior after a wash, also our other 'proper' camper sneaking into the shot.

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Now a second set of images showing the interior as installed by the previous owner/converter.

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The camper interior is quite rough but its a good starting point. It rattles a lot when driving though which is extremely annoying. We'll be working through improving things over the next few weeks/months.

Over the weekend we have:
  • Given it a full service - fixed a few leaks in the process
  • Checked codes on OBDEleven - New right front ABS sensor required (no dash error light though and ABS works?) and an Aircon re-gas is also required
  • Removed the black vinyl on the rear windows
  • Stripped out the old BG wiring which had been left in
  • Removed all the cupboard doors to paint
  • Fitted a bigger leisure battery
  • Re-wired the split charge system which was routed poorly

I've got a bunch of little niggles to sort on the van and mods to do, not related to the camping interior. These include: Refurbishing the wheels, fitting a new rear door latch, removing any remaining BG wrap, replacing the parking sensors, fitting a rear view mirror... The list goes on.
archievasarchie
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by archievasarchie »

Awesome van, can’t wait to see what else you do with it and how it come along on your VW journey!
sewi
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sewi »

Nice van. Guess you won't do too much in terms of mods as it is camper only. Am I right? What is the front interior now?
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

The front interior is the standard fit for the van, part leather(ette?) and fabric. Standard dash and all that.

I won't be doing anything extreme mod wise, or at least not in the short term.
Might look at some other seats in the future. The old T2/Bay has full leather Audi A6 seats in it which are nice, probably look for something similar.
Last edited by Giddy on Mon Mar 28, 2022 9:46 pm, edited 1 time in total.
Reason: removed unnecessary quote of previous post
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

Couple of updates from the last few days..

Fitted Solarplexius tint panels to the rear windows.

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They very extremely easy to fit and the level of light transmission appears to be about perfect.

Fitted a DAB & FM sharkfin aerial in preparation for a radio upgrade to an RCD 310.
I have also completely removed the old BG aerial mounts, the holes are now sealed with 13mm plastic plugs and clear polyurethane sealant/adhesive.

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It may not be obvious in the previous images but the cut out in sliding door for the window looked like it had been done with a knife and fork, and it also overlapped with the black edge of the glass. So I've trimmed the opening as much as I can without cutting out the bonded area.
After increasing the opening size I painted inboard of the double skin door section satin black. Now when I fit another window in the other sliding door they will look similar.
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makzimum
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by makzimum »

Are you happy with the solorplexius tints? Are they fairly solid once installed? I was slightly concerned they might rattle a bit.

I'm thinking about getting the full set for my maxi life. I've been talking to them and they have a set which fits the little sliding windows in the rear doors which I was pleasantly surprised about.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

I am happy with the Solarplexius tints and the fitting.
They don't fit up tight against the pane of glass in the centre on the rear doors, but this doesn't seem to affect them. I havent noticed any knocks or rattles from them with the supplied adhesive stops/spacers fitted.
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makzimum
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by makzimum »

Great, sounds good.

I like your old camper, you should wrap the top half of the caddy in white and make them match :lol: :lol:
tea_and_cake
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by tea_and_cake »

Great van, love the conversion, looks vey tidy. Amazing what you can fit in the back of these things.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

Quite a bit more work done over the weekend.
Pulled all of the interior out including carpet and removed the trim panels. Any existing insulation was removed where it could be improved.

We then applied more sound deadening to critical areas before stuffing all cavities with recycled plastic insulation.

During the process I replaced the reversing sensor kit. Well actually two kits, as there were two in the offside rear cavity, neither of which worked.
I also found a length of 15mm copper pipe and a pair of women's leggings in that same offside rear cavity... I guess the copper pipe can be explained with the vans history, I'm not sure what the story behind the leggings is though!

Using some of the carpet previously removed from the van sides I carpeted the rear door panels.

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I cut out and fitted the nearside sliding door window. Glass supplied by Camperglass to match the existing offside sliding door glass.
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A few other jobs done that I didn't get pictures of are:
  • Nearside barndoor lower latch replaced
  • Leisure battery moved rearwards into the underfloor cavity and a clamping mechanism fitted
  • Electrics from leisure battery to the side unit completely rewired and re-routed using the stripped out BG cabling and fuse box
  • Changed the front interior light for the version with separate map lights, vastly improving the cab area visibility when it's dark
  • Replaced both front wing mirror glass and heated pads as they were not working
Berserker
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by Berserker »

Great use of space, for a small van it seems surprisingly spacious! Nice work.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

A bit more progress over the last few weeks.

Completed the carpet lining in the rear.
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Removed the old flooring and replaced with self adhesive vinyl tiles. Interior then re-fitted.
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Thoroughly cleaned the front seat fabric and then dyed the material dark grey. The intention was to make the original seats look a bit fresher. Its roughly acheived what I hoped but one shade darker of dye may have been better.
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Repaired some minor damage to the front bumper, filled, sprayed with textured paint and then applied liquid shoe polish to the entire bumper. Really happy with how this has turned out.
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Same process on the back bumper, no repairs.
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Started building a slide out chemical toilet and putting some cupboard doors back on.
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In addition to all of the above I have also replaced the front right wheel bearing and outer CV joint. The bearing appeared to fail shortly after I had replaced the ABS sensor on the same side, and in the process of removing the bearing from the hub the CV joint was damaged. Ended up a more expensive job than I hoped, but the replacement has resolved a intermittent ABS fault I could see in OBDEleven.
Whilst I was doing this work I removed and cleaned up both front brakes, I have painted them satin black. I'll do the rears later when the wheels come off for a refurb.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

Bit of an image dump from the last few weeks of progress.

New worktop cut out properly to match the side profile of the van. Sink relocated to allow for a wide drawer to be added to the unit.

Curtains fitted, Shore vans grey on the windows and grey Dunelm ones for the cab divider.

Rally style PVC mudflaps installed.

Slide out chemical toilet set up finished, vast majority of the cupboard doors done. I have now added the drawer mentioned above but I don't have photos yet.

We had our first night out in the van last weekend, all went reasonably well. It takes a bit of acrobatic skill to use the chemical toilet in the night but that was expected with the space available.

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Other than the conversion work which I have images for I also traced a slight oil weep on the engine, it turned out to be the dipstick tube which had been broken right where it entered the engine case. I suspect this happened when the oil cooler was changed not too long ago.
It was bit of a nightmare to remove without stripping the front end, spent an hour or so trying to get large self tapping screws to bite into the section of tube remaining in the case. I had all but given up and was ready to drop the sump when it finally came free.
I bought a good used tube off eBay but I didn't realise untill I came to fit it that the intake manifold had to be removed.
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Anyway I finally got it fitted and everything back together, but it's a job I wish I never started!
There were no drips of oil for a few days so I was confident it was fixed, so I could then fit a full insulated undertray I'd picked up.

I have one last mechanical problem to solve (hopefully!) which is a bit of vibration between 60-70mph. Swapping wheels front to back made it quite a bit better initially but I think it's starting to worsen again. So it's booked in for the tracking doing on Friday as I think it might be tyre wear/abnormal tyre loading related. If not I can only imagine the wheels need rebalancing which will be done when they are refurbed.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

It's a while since my last update.
Quite a bit of change.

I've had my first failure of a B suffix injector, about 10 minutes from home after a good 200 or so mile journey back from Scotland. Replaced by AA on my drive with the parts and garage cover, cost me just a little more than the excess.

After being scammed on one of the Caddy Facebook pages by a so called breaker, I eventually a sourced another bulkhead and rear door threshold trim.
I cut the bulkhead down to fill the gaps on the B pillars.
Fitting the trimmed bulkhead pieces and the threshold finished the camping interior off.
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I have retrofitted cruise control and trip stalks, coded in with OBDEleven. Then wrapped the steering wheel with a sew on alcantara/suede type material, will see how well that wears! I don't have pictures of these.

Tracking didn't solve the vibration but the garage did identify that the rear control arm bushes were past their best, so I replaced the complete lower arms with new ZF Lemforder units C/W bushes.
Since then I've had the wheels refurbished and powdercoated. This included balancing the wheels when the tyres were refitted. Still no luck, same pulsating vibration at 60mph or so.
In my opinion the wheels look awesome now though. The colour is a copper candy.
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In these photos you'll also spot I've fitted some roof bars and a humongous roof box. The roofbox was a Facebook marketplace find but was much bigger than I'd anticipated when I collected it!


Currently I'm working through fitting new top mounts to the front shocks as these appeared to have a bit of vertical movement when the front suspension was cycled up and down. I've also got a knock from the front end when driving on poor roads; might be the top mounts, maybe the drop links (also being replaced with Meyle HD ones) or possibly the steering rack pre-load. It's likely all 3 are contributing factors, although the latter most I won't be able to resolve without a complete refurb rack. I think so i'll have to live with whatever knocking is left after all the other suspension component replacements.
Through the top mount replacement process I've had to remove the CV's from the hubs so I've also removed, cleaned the mating faces and refitted the wheel bearing I fitted a few months ago. I've done this to hopefully remove any potential that it's the bearing or the CV connection to the bearing causing the pulsating vibration.

If none of this work resolves the pulsating vibration I might have to consider replacing the driver's side axle completely in case it's out of balance or something. I'm fairly confident it originates in that area and there's nothing else I can think of that would cause a vibration.
sssingletrack
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Re: Ex-BG Maxi Micro-Camper/Daily

Post by sssingletrack »

Top mounts replaced, and the rest... Still pulsating and knocking on rough roads.
I'll be leaving both those issues for now, get some mileage done and probably look at it again towards the end of the year.

I've taken pictures of the suede type steering wheel cover and cruise/trip stalks.
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Couple of other additions/changes over the past week are a Maxton Designs spoiler, black painted VW logos and a rubber universal front splitter lip.
The front splitter looks quite bad in my opinion as it's rippled across the front edge, I'll probably remove it and fit a proper TRC, Maxton or similar in the coming weeks.
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