Fitting Caravelle seat rails

[ldm82]

How long would it take to remove the rails from start to finish?

It took me a day, I'm sure it can be done quicker but I took my time as it was a brand new van. You need to drop the fuel tank to do it, my one is a 4motion also so was a bit tight getting the ones above the rear diff done.

Other than that nothing too complex to it, there are holes in the chassis cross members where the holes need to go.

 

[Skyliner33]

Hi, the ones I bought were the caravelle ones, as you say, not many about the right height for the cali bed. I cut them down to height and welded (well splattered some weld about the join) a replacement longer base on them, this allowed them to overhang the end of the rail given it is a swb rail but still have two fixing points on the rail. On the overhanging bit I put a wee plastic foot on to keep it the same height. All pretty solid when in place.

I'm away this weekend so can't get photos, although do have this one on my phone. Hopefully that's a bit clearer, shout if there are questions.....

View attachment 135612

Thank you. Thats helpful. I will have to get someone who can weld to do that for me.
Did you have to make a new board on top?
Pictures would be great thanks.
Also one of where the front of the rails go, like this:

 

[Spazpecker]

It took me a day, I'm sure it can be done quicker but I took my time as it was a brand new van. You need to drop the fuel tank to do it, my one is a 4motion also so was a bit tight getting the ones above the rear diff done.

Other than that nothing too complex to it, there are holes in the chassis cross members where the holes need to go.

Thanks. I also have bought a 4mo. But im asking about removal because I have bought a set and have to remove them myself. I've asked the guy to remove the fuel tank etc

 

[ldm82]

Thanks. I also have bought a 4mo. But im asking about removal because I have bought a set and have to remove them myself. I've asked the guy to remove the fuel tank etc

Ah, sorry - misread the post. I'd think you'd be able to get them all out start to finish in a couple of hours including dropping the tank.

 

[ldm82]

Thank you. Thats helpful. I will have to get someone who can weld to do that for me.
Did you have to make a new board on top?
Pictures would be great thanks.
Also one of where the front of the rails go, like this:

View attachment 135619

View attachment 135620

Sure, I'll grab some pics tomorrow when I'm home.

 

[ldm82]

Thank you. Thats helpful. I will have to get someone who can weld to do that for me.
Did you have to make a new board on top?
Pictures would be great thanks.
Also one of where the front of the rails go, like this:

View attachment 135619

View attachment 135620

Managed to grab the picture today, this is the rail behind the handbrake measured from the base of the drivers seat. Hope this helps.

 

[Skyliner33]

Managed to grab the picture today, this is the rail behind the handbrake measured from the base of the drivers seat. Hope this helps. View attachment 135976

View attachment 135977

Thank you.

 

[Skyliner33]

Cali rails don't need the additional plates (Advised by 3 independent VW conversion specialists) However the Caravelle / double rails do > designed to carry more seats / load?
I fitted mine myself.
Positioning:
They naturally fit into the floor channels provided.
Location within the channels. Once you've removed the underfloor heat shields and plastic covers you'll see that the floor cross members already have holes stamped into them. It's a case of not all holes are used. I located the most forward securing hole and worked backwards. Don't fit them to close to the front seats as you'll not be able to install your bed using the access slots at the front. It's pretty damn close anyway!!
Once you know the floor anchor locations, you can work out which ones line up with the rail holes. Hope it makes sense.
Mine's a LWB and found they didn't totally match so drilled the rails (Square holes!!)

How did you 'drill' square holes?

 

[DXX]

You can use a broach or a square file, I would think the file would be cheaper and easier in this situation.

 

[Skyliner33]

You can use a broach or a square file, I would think the file would be cheaper and easier in this situation.

A woman’s badge?

 

[DXX]

A woman’s badge?

What is Broaching? | What is the Broaching Process? | Miller Broach

The machining process that uses a toothed tool to remove material is a consistent and accurate way is called broaching. Learn more here.

www.millerbroach.com

You need a means to push it through, if you had a portable drill press that would do it.
I’d go for a square file or of you have access & two people you could use this

Metric Hole Punches | Cromwell Tools

Cromwell Tools - Experts in Hand Tools, Power Tools, Cutting Tools and PPE

www.cromwell.co.uk

 

[Skyliner33]

What is Broaching? | What is the Broaching Process? | Miller Broach

The machining process that uses a toothed tool to remove material is a consistent and accurate way is called broaching. Learn more here.

www.millerbroach.com

You need a means to push it through, if you had a portable drill press that would do it.
I’d go for a square file or of you have access & two people you could use this

Metric Hole Punches | Cromwell Tools

Cromwell Tools - Experts in Hand Tools, Power Tools, Cutting Tools and PPE

www.cromwell.co.uk

Thats interesting. Might have a go with a square file and if it takes to long a friend of a friend I'm sure can do that.

Ps those punches all make round holes not square.

 

[Spazpecker]

The square part is in the rail, it holds the bolt whilst you tighten the nut?!

 

[Skyliner33]

The square part is in the rail, it holds the bolt whilst you tighten the nut?!

Yes.

 

[DXX]

Thats interesting. Might have a go with a square file and if it takes to long a friend of a friend I'm sure can do that.

Ps those punches all make round holes not square.

Sorry about that punch link, they do exist, just the minimum size I can find is 19mm on Amazon.

Q.Max Q. Max - Square Sheet Metal Punch 19mm : Amazon.co.uk: DIY & Tools
Use a ‘b@stard’ grade file and it’ll rip through, that’s the correct term.

 

[Spazpecker]

Sorry about that punch link, they do exist, just the minimum size I can find is 19mm on Amazon.
View attachment 137846
Q.Max Q. Max - Square Sheet Metal Punch 19mm : Amazon.co.uk: DIY & Tools
Use a ‘b@stard’ grade file and it’ll rip through, that’s the correct term.

Always sniggered in engineering class at the b*****d file!

 

[DXX]

Always worth spending the extra £ for a handle, that tang can do far worse damage than this.
When I was an apprentice they showed a film with the file tang going all the way through a wrist. Then it really is a bast@rd.

 

[Skyliner33]

Always worth spending the extra £ for a handle, that tang can do far worse damage than this.
When I was an apprentice they showed a film with the file tang going all the way through a wrist. Then it really is a bast@rd.


View attachment 137847

I can imagine.

Anyone know what this tool is called? OR where I can get one?

 

[DXX]

I can imagine.

Anyone know what this tool is called? OR where I can get one?

It’s running eccentric, you need a fixed machine which would mean a magnetic base or bolting it to the floor.
I reckon you can file a hole in less than 10 minutes

 

[Skyliner33]

It’s running eccentric, you need a fixed machine which would mean a magnetic base or bolting it to the floor.
I reckon you can file a hole in less than 10 minutes

A friend has one if the big fixed drills.