It's been awhile since I've posted and have quite a few pics to upload to cover details of the build. The bus is on the road and driving! I've been using it to commute to work and back, we've taken a 150 mile day trip loaded with kids and dog, and have done a lot more work beyond the conversion since the last post.
First up though, I want to provide some detailed pictures of the rear support bar. I tired to create my own version and quickly realized my effort was not very good. I had Dan Coy of Coy's Customs in Longmont Colorado rebuild the bar and his design is simple and clean.
I started with a Vanagon cross bar and ground off the hanger supports and then shortened the bar to span the frame rails.
Dan did a better job:
First, he added a plate the is welded to the end of the bar and extends toward the front of the bus along the outside of the frame rails. The bolt holes actually align with the bunged bolt holes for the original VW crossbar hangers. No fuss, no muss.
On the inside of the frame rails, he added a simple plate to reinforce the hanger and provide a bit more structural support. The rear bar doesn't actually support the weight of the engine, it provides support for torque and rotation. The Vanagon bar of course mounts perfectly to the Small Car engine carrier with stock Vanagon rubber mounts. Clean, simple, and effective.
In the photo above, you can just barely make out the steel plate on the inside of the frame rail with the two bolts that pass through the stock VW hanger bolt holes as well as a horizontal tab that bridges the bar and the plate on the outside of the frame rail (creates yet more rigidity).
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