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.
 
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:

F0DBAE3E-DD5F-4F39-9B0E-B5A85E3FAF5A.jpeg

D2653B75-52FE-49C5-AEC2-EEEC54B67E69.jpeg
 
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
 
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.
 
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. 20211109_162708.jpg

20211109_162648.jpg
 
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?
 
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?
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
 
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
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.
 
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.


1638107176731.jpeg
 
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?

 
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
 
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.
 
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