{"id":5292,"date":"2019-12-20T09:07:38","date_gmt":"2019-12-20T09:07:38","guid":{"rendered":"https:\/\/www.thebeast.blog\/?page_id=5292"},"modified":"2026-03-22T12:04:44","modified_gmt":"2026-03-22T12:04:44","slug":"mechanical-and-electrics","status":"publish","type":"page","link":"https:\/\/www.thebeast.blog\/?page_id=5292","title":{"rendered":"Mechanical and electrics."},"content":{"rendered":"

Completed <\/em>mechanical and electric work.<\/em><\/strong><\/h3>\n

The list below covers the Mechanical and electrical items we have fitted or modified on the van.
\nFor the list of all the mechanical and electrical work planned, in progress, or completed, see Permanently fitted or available complete list, 1.<\/span><\/a><\/span><\/em><\/strong><\/p>\n

The headings in \u201cBlue<\/span>\u201d below provide a link to related items from all categories & include the items we intend to make, modify or buy.<\/strong><\/em><\/p>\n

The items in \u201cblack<\/span>\u201d are completed. (some with links to more information).<\/span>
\nAny items in \u201cmauve<\/span>\u201d need to be replaced, upgraded, or we need more ASAP.
\n<\/strong>The items in \u201cGreen<\/span>\u201d are almost completed.<\/strong>
\nThe items in \u201citalics (any colour)<\/em><\/span>\u201d are also listed in another category. (see links).<\/span><\/strong><\/p>\n

 <\/p>\n

I will add links to reviews and more information ASAP.<\/strong><\/span>
\n<\/em><\/p>\n

        <\/span><\/em><\/strong>Engine.<\/span><\/em><\/a>
\nEE20 Subaru engine<\/a>. (removed, see follies<\/a>).<\/span>
\n1900 TDI AHU engine<\/a>.<\/span> (replacement for the Subaru).
\nReplace the accelerator cable with an electronic accelerator pedal. (see ECU<\/a> ).<\/span><\/em><\/span><\/span><\/span>
\nHigh torque, gear reduction starter motor<\/a>.<\/span>
\n<\/span><\/h4>\n

     <\/span>Engine control<\/em><\/span><\/a>.<\/em><\/span>
\n<\/span>ECU for EE20 Subaru engine<\/a>. (now removed, see follies<\/a>).<\/em><\/span>
\nECU for 1900 TDI AHU engine<\/a><\/span>.<\/span>
\n<\/span>New ECU junction box.
\nElectronic accelerator pedal.<\/span><\/h4>\n

     <\/em><\/span> Fuel system<\/span><\/em><\/a>.
\n<\/span><\/em>Original fuel tank.<\/a>
\nStainless steel straps fitted on the original fuel tank<\/a><\/span>.<\/span><\/h4>\n

   <\/em>   Oil system<\/a>.<\/span>
\n<\/em><\/span>Items to come.<\/em><\/span><\/h4>\n

     Charge cooler system<\/a>.<\/span><\/em><\/span>
\n<\/a>The old Subaru charge cooler<\/a>. ( moved for AHU engine).<\/span>
\nTDI AHU engine charge cooler. (new position)<\/span>
\nIntegrated main, charge cooler & air-con rad<\/em><\/a>. <\/em>(<\/em>see engine cooling<\/a>).<\/em><\/span>
\nReroute charge cooler pipework.<\/span> (to allow for storage\/battery compartments).<\/span><\/h4>\n

      <\/span> Engine air supply<\/span><\/a>.<\/span><\/em>
\n<\/em><\/strong><\/span>Items to come<\/strong><\/em><\/span><\/h4>\n

      Engine cooling<\/a>.<\/span><\/em>
\n<\/span><\/em><\/strong><\/span>New water expa<\/span>nsion tank. <\/span>(fitted with AHU engine).<\/span>
\nReroute radiator pipework.<\/span> (to allow for storage\/battery compartments).
\n<\/span>Integrated main, charge cooler & air-con rad<\/a>.<\/h4>\n

       Engine bay cooling.<\/span><\/em>
\n<\/em><\/strong>Items to come<\/strong><\/em><\/span><\/h4>\n

      Exhaust system<\/a>.<\/span><\/em>
\n<\/em><\/strong><\/span>Stainless steel exhaust system for Subaru<\/a>. (removed).<\/span>
\nSubaru turbo<\/a>. (removed).
\n<\/span>Turbo for 1900 TDI AHU engine.
\nStainless steel exhaust system for 1900 TDI AHU engine.<\/span><\/h4>\n

       <\/strong><\/em><\/span>Drive train<\/span><\/em><\/a>.<\/span><\/em>
\nSubaru dual-mass clutch & thrust bearing<\/a>. ( now removed, see follies<\/a>).
\n<\/span>1900 TDI, dual-mass clutch.<\/span>
\nNon-return valves on the clutch servo bleed point<\/a>.<\/span>
\nUpgrade the gear selector lever.<\/span> (temporary until cable gear linkage is installed).<\/span>
\nUpgraded gearbox<\/span><\/a>.<\/span>
\nCable gear linkage<\/a>.<\/span> (should also allow for a second full-size underslung box).<\/span>
\nDecoupler<\/a>.
\nOld Propshaft<\/a>. (now removed, see follies<\/a>).<\/span>
\nPropshaft with sliding joint<\/a>.
\nViscous coupling serviced<\/a>.
\nFront & rear ATB differentials<\/span><\/a>. <\/span><\/span><\/span><\/span>(Automatic Torque Biasing<\/span><\/strong><\/em>).<\/span>
\n<\/span><\/span>CV boot protector.<\/span><\/h4>\n

      <\/span><\/em>Suspension & Wheels<\/span><\/em><\/a>.<\/span><\/em>
\nBushes replaced with poly bushes where possible<\/a>.
\nGo-westy progressive springs<\/a>. (front ones fitted).<\/span>
\nAdjustable front ride height<\/a>.
\nAdjustable shocks front & back<\/a>.
\n16\u2033 trailing arms<\/a>.
\n<\/strong><\/a>Wheel spacers<\/a>. (front & back).<\/span>
\n16\u2033 rims with A\/T  235-70-R16 tyres<\/a>.
\nAll-terrain tyres<\/a>.<\/h4>\n

       <\/em><\/strong><\/span>Braking system<\/span><\/em><\/a>.<\/span><\/em>
\nUp-rated brake servo<\/a>.
\nUprated front disk brakes<\/span><\/span><\/a>.<\/span><\/span>
\nUprated back brakes<\/a>. (disks fitted).
\n<\/span>Non-return valves on brake bleed points<\/a>.
\nRerouted the back brake pipes. (over trailing arms).<\/span><\/span>
\nReroute the handbrake cable.<\/span> (to allow for a second underslung storage box).<\/span><\/h4>\n

      <\/span>Steering<\/span><\/a>.<\/span>
\n<\/span><\/a><\/em>Factory-fitted hydraulic power stirring<\/a>.
\nEngine-driven power steering pump.<\/span> (on 1900 TDI AHU engine),<\/strong><\/span>
\n<\/span>Electric power steering pump<\/a>. (removed with the Subaru engine).
\n<\/span><\/h4>\n

      <\/span>Electrics<\/span><\/em><\/a>.<\/span><\/em>
\nBatteries moved to the underslung box under the floor<\/a>.
\nStarter battery moved to engen bay<\/a>.<\/span>
\nThe new dashboard<\/a>. (overview, see <\/span><\/span><\/em>Dashboard<\/a><\/em>).<\/em><\/span>
\nFuses replaced with circuit breakers<\/a>.<\/span> (some left to change).
\n<\/span>Van wiring harness.
\nDashboard wiring harness.<\/span>
\nEngine wiring harness.<\/span>
\nLarger starter battery<\/a>.
\nTwin leisure batteries<\/a>. (fitted, not wired in yet).<\/span><\/span><\/h4>\n

      Lighting<\/a>.
\n<\/span><\/em>LED indicator lights.<\/span>
\n<\/em>LED approach lights in the front indicator housings.
\nLED DRLs in front fog light housings. (under consideration, if legal).<\/span><\/span>
\nLED light bar on the front of the roof rack.<\/span>
\nLED high-level hazard lights at the front.<\/span>
\nLED twin front fog lights.<\/span>
\nLED side lights<\/span>
\nFully LED rear light clusters.<\/span>
\n      LED side lights \/ DRLs. (linked with the front DRLs).<\/span><\/span>
\n      LED indicator lights.<\/span>
\n      LED twin rear fog lights.
\n      LED brake lights.<\/span>
\n      LED reversing lights<\/span>.
\nLED rear corner ground illumination. (concealed underneath, on with reversing lights).<\/span><\/span>
\nLED high-level hazard lights at the back.<\/span>
\nLED floodlights on each side at the rear.<\/span> (possibly linked with reversing lights).<\/span>
\nLED internal van lighting.<\/span>
\n<\/em>Front overhead courtesy lights.
\nMap light.<\/span><\/h4>\n

      Dashboard<\/a><\/em>.
\n<\/span>The old dashboard<\/a>. (and the planned upgrades<\/span><\/span>).
\n<\/span><\/span>The new dashboard.<\/em><\/a><\/span>
\n     The new dashboard’s basic construction<\/a>. (the metalwork).<\/span><\/span>
\n     Switch layout<\/a>.<\/span>
\n     USB & power outlets<\/a>.<\/span>
\n     Communication & Navigation Systems<\/a>. (CB, Wi-Fi, phone, & radio).<\/span><\/span>
\n     Heating & ventilation control system<\/a>.<\/span>
\n     Arial connection panel<\/a>.<\/span>
\n     Vacuum switch system<\/a>. (diflock controls).<\/span><\/span>
\n<\/em>Clock binnacle<\/a>.<\/span> (extra clocks still to add).
\nStirring column cowl.<\/a><\/span>
\n<\/em>Overhead switch panel<\/a>.<\/span> (see switch connections<\/a> for more info).<\/span><\/span><\/h4>\n

      Heating, Cooling & Ventilation<\/a>.
\n<\/span><\/em>Remove the old air conditioning unit.
\n<\/em>Reposition ventilation & heating controls<\/a>.<\/span> (see dashboard modifications<\/a><\/span><\/em><\/span>).<\/span>
\n<\/em><\/span>PWM fan control<\/span>.<\/span> (see <\/span>dashboard modifications<\/a><\/span>).<\/span>
\n<\/em>Move the air-con controls to the dashboard<\/span><\/em><\/span><\/a>.<\/span><\/em><\/span> (see <\/span><\/em>dashboard modifications<\/a><\/em>).<\/em><\/span><\/h4>\n

      <\/span>Driving aids<\/span><\/a>.<\/span>
\n<\/strong><\/em>Reversing camera for the dashboard head unit. (needs wiring fixed).<\/span><\/span>
\n<\/span>LCD display, driving mirror and rear camera. (camera height to be decided).<\/span><\/span>
\nElectric heated rear window.
\nFix the electric window winders.<\/span> (intermittent problem needs investigation).<\/span><\/span><\/h4>\n

       <\/strong><\/em><\/span>Safety equipment<\/span><\/em><\/a>.<\/span><\/em>
\nFire extinguishers<\/a>. (must be available quickly).<\/span><\/em>
\nCO2 smoke detectors. (need replacing).<\/span><\/em>
\nAutomatic fire suppressant system in the engine bay<\/span>.<\/span> (needs installing, ASAP).<\/span>
\n<\/em>High-level rear brake lights.<\/span> (see lighting<\/a>).<\/span>
\n<\/em><\/h4>\n

      <\/em><\/span>Communication & Navigation systems<\/span><\/em><\/a>.<\/span><\/em>
\nSat-Nav head unit<\/a>, (<\/a><\/span>see dashboard<\/a>).<\/span>
\n<\/em>Compass and clino.<\/em><\/span> (see dashboard<\/a>).<\/span>
\n<\/em>CB aerial connection. (see dashboard<\/a>).<\/span><\/em><\/h4>\n

       Traveling comforts<\/span><\/a>.<\/span>
\n<\/span><\/em>3000W\/ 6000W Pure Sine Wave Power Inverter<\/a>. (<\/span><\/em><\/span>see wild camping)<\/a>.<\/em><\/span><\/h4>\n

        <\/span>Of road additions<\/span><\/a>.<\/span>
\n<\/span><\/em>All-terrain tyres<\/a>.  (see suspension & wheels<\/a>).<\/span>
\n<\/em>Reinforce the engine cradle<\/span><\/a>. (may not be needed for AHU engen)<\/span><\/span>
\nModified front bash plate<\/a>. (with storage facility).<\/span><\/span>
\nModified sump guard<\/span><\/a>.<\/span>
\nUprated front winching attachment points<\/a>.
\nUnder-slung sand ladder racks on the roof rack<\/em>. (see recovery kit<\/a> for <\/em>sand ladders<\/a>).<\/span>
\nLED light bar on the front of the roof rack. (see lighting<\/a>).<\/span>
\n<\/strong>LED floodlights on each side at the rear. (see lighting<\/a>).<\/span><\/em><\/span><\/h4>\n

      Wild camping<\/a>.
\n<\/span>Twin leisure batteries<\/a>. <\/span>(fitted, not wired in yet, see electrics<\/a>).<\/span><\/em>
\n3000W\/ 6000W Pure Sine Wave Power Inverter<\/a>.
\n<\/span>Twin 60W solar panels on the front of the rack<\/a>. <\/em>(see wild camping<\/a>).<\/em><\/span><\/span><\/h4>\n

 <\/strong><\/em>     Long-term protection<\/span><\/a>.<\/span>
\n<\/em><\/span>Automatic f<\/span>ire suppressant system in the engine bay.<\/span> (see safety equipment<\/em><\/a>).
\n<\/span><\/h4>\n

 <\/p>\n

 <\/p>\n

For a list of all the mechanical and electrical work planned or completed, see the Permanently fitted or available complete list, 1<\/span><\/a>.<\/span><\/em><\/h4>\n

Categorie link pages:-
\n<\/strong>    Reviews<\/a>.
\n            Permanently fitted or available<\/a>
\n<\/a>                       Mechanical and electrics.<\/span><\/p>\n

Thanks for reading.
\n\"\"<\/h4>\n

.<\/p>\n

 <\/p>\n

\"\"<\/strong><\/p>\n

 <\/span><\/h4>\n

 <\/strong><\/em><\/span><\/h4>\n

 <\/h4>\n

 <\/h6>\n","protected":false},"excerpt":{"rendered":"

Completed mechanical and electric work. The list below covers the Mechanical and electrical items we have fitted or modified on the van. For the list of all the mechanical and electrical work planned, in progress, or completed, see Permanently fitted or available complete list, 1. The headings in \u201cBlue\u201d below provide a link to related … <\/p>\n

Continue reading “Mechanical and electrics.”<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"parent":411,"menu_order":1,"comment_status":"closed","ping_status":"closed","template":"","meta":{"ngg_post_thumbnail":0,"footnotes":""},"class_list":["post-5292","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/pages\/5292","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=5292"}],"version-history":[{"count":231,"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/pages\/5292\/revisions"}],"predecessor-version":[{"id":22889,"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/pages\/5292\/revisions\/22889"}],"up":[{"embeddable":true,"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=\/wp\/v2\/pages\/411"}],"wp:attachment":[{"href":"https:\/\/www.thebeast.blog\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=5292"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}