Frame Reinforcement
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Everyone always asks what was done to make the stretch strong enough to take the load. the truth is that the stock vanagon is plenty strong enough to take the extra length. But the fact is that this will see much overloading and probably some decent offroading. Jumping with the tires a foot off the ground is not unheard with my driving style.
For peace of mind I reinforced the frame at the junction.
The square tubing is 1.5" X 3" .090" wall cold rolled steel. I used 2 pieses 4 feet long each.Very standard stuff that happens to fit inside the VW frame nicely. It helps to be lucky!
I drilled holes in original frame and then plug welded to the square tubing which slides inside them.
The two frame reinforcement members re welded into the back half. It makes a perfect way to hold the front half while it is being lined up.
