straypoet
Active member
Hello everyone. I have decided to base my build thread here; as opposed to the TDI Forums, or the regular Jeep forums, though I have some partial threads there. I hope that by documenting my progress here (and on Youtube) I will be able to also inspire others to build their own.
I have a 2007 JK that I am basing this project on. My goal is to take much of the ideas from the expedition campers I have seen built on the Land Rover Defender 130s, and use them to create a custom vehicle that I plan to use for about 25 years.
I live in the US, and the ideal (in my view) vehicle to build one of these on.... is the defender 130, but they are nearly impossible to get in good shape in the US without spending more that I expect to have in the whole conversion to just get an older defender here. Also; parts for the defenders are hard to get in the US. I have always liked wranglers (this is my 3rd), and since it is paid for, and has no rust, (Florida jeep) I think it will be a good candidate for this conversion.
I have been thinking of this kind of a project for several years, and my inspirations are from the list of people who have made these hard-sided composite campers over the years. The platform isn't all that important. My favorites cross some of the different types of vehicles available; but they all have something of interest that I hope to use in my own project.
Some of my inspiration comes from:
AEV Outpost II - Wrangler
Wild Fennec - Defender 110
Everlanders - F-550
The A2A Expedition - Defender 130
The project will take at least another year, and possibly two.
My budget for the conversion is $20,000 for the basic conversion, with another $10,000 expected over the next few years for additional upgrades and changes.
---------------------------
This section for sub-threads on this project. I won't cloud up this thread with the details that are related to things outside of the larger scope of the project, but I will link them here:
My Thread on TDI Club detailing the electrical and mechanical side of the TDI Conversion.
Thread on controlling the Brushless DC Motors for the Hybrid side of the conversion.
----------------------------
Youtube Video Links:
Links to videos that I have published on the conversion.
BHW TDI Engine Running On Test Stand
JK130 December 2021 Update #1
JK130 Project Update #2, December 24th 2021
JK130 Part 3 Transmission, Engine Mounts. Jan 05, 22
JK130 Intake Modification. TDI BHW to BRM modification
JK130 Part 4, March 2022 , Balance Shaft Delete, Intake, Engine Work
JK130 Part 5, April 2022 Engine In the Frame.
JK130 Part 6, Engine Mounts DONE April 2022
JK130 Update 7 June 2022 Work on Intercooler and Radiator on my TDI swapped Jeep Wrangler JK.
JK130 Part #8 Charge Pipes, Inner and Outer Fenders, Accessory Trays
JK130 Part 9 Engine Coolant System Oil filter and cooler wiring harness, TDI BHW Swap
JK130 Part 11 TDI Swap Into Jeep Wrangler Expedition Vehicle Work on Exhaust, Seats, Wiring, Battery
JK130 Part #12 ENGINE RUNNING!! Seat work, and new battery
JK130 Part #13, New Bumper, N75 Valve, Wiring Seats bolted Down
Goal Tracking.
I will try to remember to keep this section updated to keep track of the current amount spent on the conversion. This cost is what I have actually spent, and will not include the cost to rent the garage, or any additional tools I buy for the project, but will include consumables used in the construction. I expect I will recoup a small amount of this in selling extra parts, scrapping stuff etc., but I won't bother to track this.
Donor Vehicle List.
For fun, I am going to track all of the parts that I use in this project that originated on different types of vehicles. I will keep updated with what I use.
I hope to take this vehicle from Alaska to Argentina, from London to Moscow, from Paris to Dakar.... You get the idea.
I will do 90% of the work myself. I can weld, I can wire, I can paint, I can wrench, I can design, I can learn what I need to learn to get the project to completion.
Lets get started by covering what has been done so far.
I have a 2007 JK that I am basing this project on. My goal is to take much of the ideas from the expedition campers I have seen built on the Land Rover Defender 130s, and use them to create a custom vehicle that I plan to use for about 25 years.
I live in the US, and the ideal (in my view) vehicle to build one of these on.... is the defender 130, but they are nearly impossible to get in good shape in the US without spending more that I expect to have in the whole conversion to just get an older defender here. Also; parts for the defenders are hard to get in the US. I have always liked wranglers (this is my 3rd), and since it is paid for, and has no rust, (Florida jeep) I think it will be a good candidate for this conversion.
I have been thinking of this kind of a project for several years, and my inspirations are from the list of people who have made these hard-sided composite campers over the years. The platform isn't all that important. My favorites cross some of the different types of vehicles available; but they all have something of interest that I hope to use in my own project.
Some of my inspiration comes from:
AEV Outpost II - Wrangler
Wild Fennec - Defender 110
Everlanders - F-550
The A2A Expedition - Defender 130
The project will take at least another year, and possibly two.
My budget for the conversion is $20,000 for the basic conversion, with another $10,000 expected over the next few years for additional upgrades and changes.
---------------------------
This section for sub-threads on this project. I won't cloud up this thread with the details that are related to things outside of the larger scope of the project, but I will link them here:
My Thread on TDI Club detailing the electrical and mechanical side of the TDI Conversion.
Thread on controlling the Brushless DC Motors for the Hybrid side of the conversion.
----------------------------
Youtube Video Links:
Links to videos that I have published on the conversion.
BHW TDI Engine Running On Test Stand
JK130 December 2021 Update #1
JK130 Project Update #2, December 24th 2021
JK130 Part 3 Transmission, Engine Mounts. Jan 05, 22
JK130 Intake Modification. TDI BHW to BRM modification
JK130 Part 4, March 2022 , Balance Shaft Delete, Intake, Engine Work
JK130 Part 5, April 2022 Engine In the Frame.
JK130 Part 6, Engine Mounts DONE April 2022
JK130 Update 7 June 2022 Work on Intercooler and Radiator on my TDI swapped Jeep Wrangler JK.
JK130 Part #8 Charge Pipes, Inner and Outer Fenders, Accessory Trays
JK130 Part 9 Engine Coolant System Oil filter and cooler wiring harness, TDI BHW Swap
JK130 Part 11 TDI Swap Into Jeep Wrangler Expedition Vehicle Work on Exhaust, Seats, Wiring, Battery
JK130 Part #12 ENGINE RUNNING!! Seat work, and new battery
JK130 Part #13, New Bumper, N75 Valve, Wiring Seats bolted Down
Goal Tracking.
I will try to remember to keep this section updated to keep track of the current amount spent on the conversion. This cost is what I have actually spent, and will not include the cost to rent the garage, or any additional tools I buy for the project, but will include consumables used in the construction. I expect I will recoup a small amount of this in selling extra parts, scrapping stuff etc., but I won't bother to track this.
Project Completion Goal: | Summer 2022 (obviously that didn't happen) | Completed: | TBD |
First Phase Budget Goal: | <$20,000 | Spent so far: | =$13305 |
Second Phase Budget Goal: | <$10,000 | Spent so far: | =$2000 |
Empty Weight Goal: | <5,700 LBS (2,600KG) | Current Weight: | coming soon |
Diesel Capacity Goal: | =40 gallons (150 Liters) | Results: | no tanks yet |
Fuel Efficiency Goal: | =>25MPG (9.2L/KM) | Results: | TBD |
Lithium Battery Goal: | =>10KWHR | Results: | no batteries yet |
Solar Goal: | =>1.14KW | Results: | no panels yet |
Donor Vehicle List.
For fun, I am going to track all of the parts that I use in this project that originated on different types of vehicles. I will keep updated with what I use.
2007 Jeep Wrangler JK | Front half of body, frame, transmission, transfer case, axles. |
2005 Volkswagen Passat TDI | Engine, Turbo, ECM, Wiring Harness, Throttle Pedal. |
2007-2018 Wrangler JKU Unlimited | B-pillar outer panels |
2019 Dodge Ram 1500 Pickup Truck with 5.7 Hemi with eTorque (X2) | 12kw Brushless Motors |
2002 VW Beetle TDI | Coolant Flange For Rear Of Engine. |
2014 Hyundai Genesis Coupe 2.0T R-Spec | Front Leather Seats |
2012 Hyundai Veloster | Gauge Cluster |
2011 Volvo S60 | Electric Power Steering Pump |
I hope to take this vehicle from Alaska to Argentina, from London to Moscow, from Paris to Dakar.... You get the idea.
I will do 90% of the work myself. I can weld, I can wire, I can paint, I can wrench, I can design, I can learn what I need to learn to get the project to completion.
Lets get started by covering what has been done so far.
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