Clubvan #2

[scrw.]

Decided to do a new thread on this one, may do some different engine tweaks on it.

As it stood a few weeks back, another 1.6D Cooper Clubvan to bring back from the dead.

Snipaste_2025-05-27_17-01-01 by Old_Chad, on Flickr

[scrw.]

So plan on this one is replace the dead engine (cam chain), look at different turbo & bigger intercooler, leather seat swapout, Journeys Offroad 2.5" lift...and various other pimping out bits. This is a better spec than my other 2 vans so will build this one to keep.

[scrw.]

PO saw fit to remove the brake pads on the black one, and given the disks were scruffy decided to replace the whole lot, having a handbrake will be handy when taking the engine out LOL. Also adding about 50BHP with some calliper paint!

20250812_190340 by Old_Chad, on Flickr

[scrw.]

Lift kit in at the rear and the brakes finished. Will give the subframe some waxoil tomorrow and fit the AT wheels on the back, then its on to getting the old motor out.

20250813_221306 by Old_Chad, on Flickr

[scrw.]

Waxoiled the rear subframe area & fitted the wheels that I had on the white one, back end complete!

20250814_193054 by Old_Chad, on Flickr

Frontend strip down started, I am going to have to get the Henry out to get rid of all the spiders and cobweb....I hate spiders!!!

20250814_193027 by Old_Chad, on Flickr

Air con & engine rad are toast, really rotten, so expect intercooler is too. Excuse to fit a larger intercooler, will see if the standard is the same as an N14 and if an N14 chinacooler will fit.

20250814_193037 by Old_Chad, on Flickr

[scrw.]

Slow progress, garage has been too toasty to work in of late, evenings are getting better now though.

Oil extraction pump decided to st the bed, is now in the skip after dumping 4 litres of used oil, nice.

20250824_175620 by Old_Chad, on Flickr

BHP added to the front brakes now, need them fitted so I can crack the driveshaft nuts, new brakes will be completed tonight.

20250825_200003 by Old_Chad, on Flickr

Splashed out on an engine stand as I don't have the space and its easier to shift it around & build it up. Big order made at the local factors for all the bolt on stuff you want to swap while the engine is out, £500+ spent, and thats before I order the DMF & clutch :-/

20250824_181406 by Old_Chad, on Flickr

20250824_181429 by Old_Chad, on Flickr

20250824_181439 by Old_Chad, on Flickr

Set about the front of the car with the hoover and evicted a load of spiders too.

[scrw.]

slow progress due to harvest, however brakes are done so I can break off the driveshaft nuts now and crack on getting the engine & box out.

20250902_184821 by Old_Chad, on Flickr

20250902_190358 by Old_Chad, on Flickr

[scrw.]

Right, apple season is over so I have my weekends and evenings back, mini time!

Front end is off, all the rads are toast, so plan is straight swap of the crashed van rad pack, didn't seem to be and damage to is apart from the very bottom of the lower crash bar, which I think we can straighten, if not we will just swap the rads over.

20251115_161656 by Old_Chad, on Flickr

Spanner assistant today

Will get the driveshafts out & exhaust disconnected next, then finish up with disconnecting to top end wires n stuff

20251115_164714 by Old_Chad, on Flickr

[21TonyK]

Good to see progress. Tough little things, hoping my F54 is as sturdy when the body shop get the bonnet open!

[scrw.]

when the chain lets go at motorway speeds....

20251120_193355 by Old_Chad, on Flickr

EGR sucks

20251120_194452 by Old_Chad, on Flickr

getting there

20251120_194600 by Old_Chad, on Flickr

1 injector was tight, took a bit of wiggling to get out. Should have the engine ready to come out at the weekend. Waiting for clutch & flywheel to arrive at the mo.

20251120_201234 by Old_Chad, on Flickr

[mike9009]

Love these updates on ordinary cars. Realised not many have posted so showing some appreciation!

[SteveV8miller]

Viewed your previous challenges, watching this one now. I would love to have the time, patients and talent, luckily for the wife I don't!

[scrw.]

Just had a big spend session on ebay for odds n sods my local factors doesn't stock like exhaust studs & nuts. Will call in with them on monday for the ancillaries to go on the engine, this time last year it cost £650 for those and £747 for the full clutch kit, lets see what it is this time! I think if you do it right you are looking at £1600 spend on bits plus the engine at £2k. Really need to get this one done soon so I can get the engine out of van #1 into #3 van and get that sold to get some money back LOL