Bongo Fury

My ultimate Bongo project - for life!

Ok so now I've got your attention here goes.......

I have potential to buy a virtually mint Bongo shell (hardtop) for utter peanuts which is identical to mine in every way apart from no rust/dents. The shell will be virtually totally bare apart from windscreen and probably dash etc. The underside hasn't been undersealed and is totally clean with only very light surface rust in places. I have seen under it on a ramp and stripped down and it clean and rot free, newish really. It would be a shame to see it squished!

My grand plan is to prepare the shell underneath fully and swap all the parts over adding a few tweaks to suit my purposes.
On a ramp/workshop if I can borrow one (I am dropping hints to my brother but not sure if he will relent) I could sand down and paint the underside and arches then underseal it totally as it is bare. Then it would last a lifetime

I would remove the rear carpet, possibly ply-board the floor and then put vinyl down. We have dogs and would like to be able to wipe down the floor as they get soooo muddy! I would then just have the middle seats as I do now.

I have a few performance plans for the engine using a custom chargecooler kit I have gathered together and have had fabricated which would be easier to fit/problem solve when the Bongo is apart. A scratch built air-box will be made.

I think the new shell is originally 2wd (not that it matter although will say in the log book) and might consider converting mine to 2wd for fuel economy purposes and will also be slightly lighter and leave more room for pipework for my engine plans. I have a limited slip diff and although with my present set-up it is fantastic in the snow it doesn't snow much in Cornwall!

I am thinking of using lowering springs but also look into raising the engine/gearbox to suit to keep ground clearance as I live in an area with lots of speed bumps/ramps. On a bongo there are only 2 engine mounts which are on a hefty crossmember and one gearbox mount which hangs it from above, modifying these should be straight forwards. The reason for lowering the Bongo would be to lower the centre of gravity as bongos do roll a bit in corners and also to reduce the frontal area to help fuel economy.

I am umming and ahhing about keeping the air-con as I would have to be degassed and re-gassed and it would be fiddly and faffy to remove and replace but it is nice to have on a run on a hot day. Removing it may help increase economy a smidge (no belt to drive although I tend to remove the belt in the winter anyway) and it would be slightly lighter and improve airflow to the engine radiator. If I did remove the air-con I would consider moving the alternator to where the air-con pump is to better route the air intake to the turbo.

If I can get garage space then the prep work on the shell I can do at my leisure within reason but once I start swapping parts over this is when the heat will be on. Our Bongo is our only transport and my wife has a bad back which means she struggles in any other cars hence wanting to keep a Bongo long-term.

I would I supose need to take a few days/a week off work to do the swap. Has anyone done a similar swap before. In my head I know I under-estimate the complexity and time consuming slog that it will be. I know a shell can be stripped in 2 days but will it go back together so easily?

I am also wondering how to move the shell about when it is being worked on - how many people would it take to move a bare shell? I am thinking through ideas of a frame and castors, any suggestions?

Also does anyone know of any work space local to Plymouth/SE Cornwall?

Any thoughts/suggestions? Russ

rustyp wrote:My ultimate Bongo project - for life!

I am thinking of using lowering springs but also look into raising the engine/gearbox to suit to keep ground clearance as I live in an area with lots of speed bumps/ramps. On a bongo there are only 2 engine mounts which are on a hefty crossmember and one gearbox mount which hangs it from above, modifying these should be straight forwards. The reason for lowering the Bongo would be to lower the centre of gravity as bongos do roll a bit in corners and also to reduce the frontal area to help fuel economy.


Any thoughts/suggestions? Russ

You’re not going to be able to raise the motor and box much and are misguided. The suspension design sets the roll centres and you will be adding mass above it so the Bongo at best will just roll more. So if trying to lower the centre of gravity it won’t.

Lowering will make no difference to the frontal area; the coefficient of drag is set by the vehicle itself.

So that has saved you a load of work then…………….

But…………….. I get where you are going, you could look at fitting a more modern, higher efficient engine and as you are starting with a blank sheet of paper it could also be petrol with an lpg tank in place of the original tank and a small start up tank?

Whatever way you go, as someone who has undertaken similar projects in the past you’re taking on a lot of work.

But don’t let me put you off................

Stick a Rover V8 in it .

Simon Jones wrote:Stick a Rover V8 in it .

Ooooohhhhhh YES

Brian

It will fit although the larger bored versions can be problematic. O………and return 15-18mpg.
The tin top works well with the 2.5 TD. That sort of power is readily available with a modern high efficiency engine, the torque is as important as the power on our heavy lump though.

The V8 is a cracking light weight lump and have one in my NG but in competition trim returns less than 10mpg…………

straight six merc out of a g wagon is what i would love to stick in mine never had any probs with that engine and found it smoother than a v8 rover

Engine will be the 2.5td lump with a number of changes. Head has already been ported by myself as the ports particularly around the valve throats are very rough. Inlet manifold will be bespoke to suit. Looking for a normally aspirated 2.5 ford ranger inlet manifold to hack up as runners are straight and I believe are bigger dia (hoping they are same size as standard head). The plan is a larger plenum for better flow distribution. Would like to go for late Ranger tdi lump but going for a common rail setup with the management to suit would be a headache!

Ok lowering car will not reduce frontal area but will reduce air travelling under car which when calculating frontal area to work out drag factor the area under the front valance/bumper is considered as part of the frontal area as part of the calculations as the effect on drag is similar (will have to dig out the formulas I used to have) so it would be virtual frontal area perhaps.

Lowering will have some effect on the roll as although the suspension pivot points set the roll centre there is also the issue that looking at the front/rear the actual tyre in roll can be considered a pivot point and the shorter the lever acting on a pivot (ie the lower the shell) the less roll, the height of a bongo being quite a lever, far less effect in a sports car. Also shorter springs are likely to be slightly firmer contributing towards roll stiffness.

Will also be paying attention to air flow around and through the front

I'm with you on the air-con.

I gave up worrying about it as soon as I learned that it is electrically engaged and even if it seized up solid it wouldn't matter (to me at any rate).

I'm a window open person. Better communication with other drivers!


Frank

Simon Jones wrote:Stick a Rover V8 in it .

And a chromed Jag IRS at the back.

Ok lowering car will not reduce frontal area but will reduce air travelling under car which when calculating frontal area to work out drag factor the area under the front valance/bumper is considered as part of the frontal area as part of the calculations as the effect on drag is similar (will have to dig out the formulas I used to have) so it would be virtual frontal area perhaps.

You are correct.
I tried to keep my reply general so as not to confuse, but as there is little ability to lower the Bongo with standard dampers an improvement in CD will be very small.
A body kit and splitter should help though.

Lowering will have some effect on the roll as although the suspension pivot points set the roll centre there is also the issue that looking at the front/rear the actual tyre in roll can be considered a pivot point and the shorter the lever acting on a pivot (ie the lower the shell) the less roll, the height of a bongo being quite a lever, far less effect in a sports car. Also shorter springs are likely to be slightly firmer contributing towards roll stiffness.

Lowering will alter the lever length but if you raise the engine and box you raise the centre of mass probably negating the reduction in lever length.
I don’t understand what you are saying about the tyre being a pivot point.
The tyre doesn’t act upon the sprung mass in roll, its position changes due to the sprung mass forces acting upon it.

Will also be paying attention to air flow around and through the front

That makes sense, what you thinking of?

blobber wrote:

Simon Jones wrote:Stick a Rover V8 in it .

And a chromed Jag IRS at the back.

Jacked up at the back, And purple metalflake with a button velour interior and porthole rear windows, slotmags and some fluffy dice. Now we're talking

Whats wrong with your existing Bongo?
What ever time you think it will take it will take longer.
A local garage holds the record near me he used to reshell accident damaged cars over night, but he only did one model, was very experianced and had done loads, the first took almost one week

My existing bongo has a creased rear quarter, rust in arches, repaired accident damage. Needs undersealing, has a bit of rust under the rear bumper/boot and a creased rear bumper hanger. It isn't too bad really but to totally go to town on the underside of a bongo to protect it for life would be great

As long as you have the time and skills to do it and realise its a big job then its fine, my only concern is I dont feel it can be done in one week unless you have a lot of help and ideally an indoor workshop.
Why not ask around a few car restoration places to see if you could rent some space for a few weeks?
Last engine swap I did was a Range rover and it took two of us two full days out side with an engine crane so I doubt you will do it in a week, why not ask a Bongo specialist incase any one has done it before?
If I was doing it I would buy another just to use whilst I did the work

hi rusty, I have a friend who has a garage in an old farm building out at Battisford farm, which is just up the A38 towards Ivybridge, but I don.t think he has a car lift. If you are interested I could introduce you to him. I would be interested in meeting up with you as you seem to have the same interst in Bongo's that I have.

Dave