More aircon in preparation for the future heatwaves. 😊 Sliding window, that seal was by far the worst to install! Took three tries to get it.

Also check out another vehicle project in local #hackerspace #makerspace recently back on the road again! https://www.youtube.com/watch?v=AZ1qq7INEWA

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Needed something easier to do while procrastinating with the metalwork and motor mounts...

This van won't be having a gear stick anymore, but I need something to switch between P-R-N-D so I found a simple 4-pos rotary switch and 3D modeled and printed a switch knob for that in original style. 😊

Files if you need: https://www.thingiverse.com/thing:6622206

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3D scanned the entire motor room and the Leaf motor. Should make things rather much easier than good old fashion cardboard aided design.

Many thanks to Arno from https://mekanisaatio.fi 😊

Firing up Fusion 360 for motor mounts in 3... 2... 1...

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👀

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With the wiper stalk slightly modified, it was time to put the steering column back together complete with the steering wheel and the horn button.

And it steers!

Still some minor lash to adjust in the steering box and cambers and tierods are probably all askew.

But it steers!

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Woo my AC is working. 😊

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To prevent rear wheel lock-up under heavy braking, a proportioning valve is used to limit the fluid pressure for rear axle.

Where some might have put a simple %-bias valve, VW has engineered something that mounts to the frame on an angle and consists of a steel ball which, under a heavy nose-dive braking, rolls "uphill" to block the passage to the rear brakes with its inertia.

One more oddity sandblasted, cleaned, painted, put back to its place. 🤯

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Taking a brake still. 😊

Plumbing just about done. Steel braided lines back and front for maximum looks. 😎

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Making threads on a lathe for the first time. 😬 Not as easy as some YouTube videos make it look like!

Tesla brake booster needed just a few cm's shorter pushrod with a yoke in the end, so instead of destroying the original I picked up some proper hard steel and started learning.

Result: Brake system almost fully functional. 😊

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Yees! Tesla M3 brake booster fits like it's meant to be in this bus!

...when you install the master cylinder the other way around and turn the whole thing upside down. 🤭

🙃

I'm still slightly amazed that the bolt pattern is almost spot-on and the only issue was with the tie rod blocking the connector. I'd have expected much worse. 🤷‍♀️

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