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    Thread: She's goin water cooled...'72 Westfalia

    1. 02-25-2011 07:09 AM #36
      Sweet job on those mounts. Are you interested in making another pair while it is fresh in your head?

      Seriously: PM me and we can talk. Your welding skills and access to powder coating seem to be better than mine.

      Craig

    2. Semi-n00b
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      1973 westfakia, 1987 Wolfsburg weekender, 1988 Wolfsburg Weekender
      02-25-2011 07:49 AM #37
      Quote Originally Posted by air skooled View Post
      westfakia

      Thanks. Yes I too am in a cramped space. Working on it 2-3 hrs a day. Planning on running a heater. I will detail it when I get to that point. I guess we will find out just how loud it is. The factory down pipe runs 15" before joining the two pipes together. There must be a reason for that. If you are going to run the radiator up front, this is a cool way to do it.

      That's "Clyde".... I have camped with him at High Country Bus Festival in North Carolina. Very well done. But I want to hide the fact that it's watercooled, so I am thinking along these lines:


    3. Member VWRedux's Avatar
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      Started NHTSA DSG Campaign/'09WolfieDSG died@623mi. VW took it back.Bought MkVI/GTI Blk 6spMT/SR/Xen
      02-25-2011 08:10 AM #38
      Just browsing around... happened onto your thread... damn... some good looking serious sh*t going on here! Great job!
      "There's nothing like a well tuned car on an open road". Paul Newman
      *The New 2011 VW Jetta... At Least You Pay Less To Get Less!*

    4. Member SauerKraut's Avatar
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      02-25-2011 12:04 PM #39
      As always, some impressive stuff going on there.

      To the guy who wants to use sintra, I'd suggest not using it like that. It's a cheap plastic that isn't intended to withstand prolonged outdoor use and will dry out and eventually become even more brittle and crack from temperature cycles, UV, etc. Even with paint on it, it'll look like crap in a short time. Go with metal or fiberglass.
      DCI FOR LIFE
      vansquad - poppin your top, bitch!

      dmiw.

    5. 02-26-2011 01:58 AM #40
      Thanks again. If your wonder why I powder coat everything, it is because I have a powder coat oven in my garage. I try to powder coat everything I build if possible. So much better than paint.

      A couple more shots of the mounts.




      Built a plate that bolts into the buses original bolt holes for the fuel pump/filter assy. Made it out of galvaized steel. I might still powder coat it. Also welded on the bolts since access to the back of the plate is limited. Still need to wire and plumb it. It looks pretty tight in there and it is, but there is clearance for everything that moves.






      Going to look for some parts tomorrow. With a little luck it will be running by the weekend and out of the garage by mid week.

    6. Member
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      02-26-2011 02:52 AM #41
      You really need to stop dick'n around and get some work done on that thing man!.....

      I;m curious to see the radiator set up...It's looking great so far.

    7. 02-26-2011 08:53 PM #42
      Real slick with that plate.

      Is there a plastic cover that goes over the pump etc? I believe there is one on the 91 parts car that I bought.

      Craig

    8. 02-26-2011 09:07 PM #43
      Of all the MKII's I've owned/worked on, I've never seen a cover. But that doesn't mean there isn't one. Picked up a bunch of little stuff today. The alternator pulley still eludes me though. I did figure out what is going on with it though. It is driven by the A/C pulley. What is needed is a non a/c alternator pulley. Not so easy to find.

    9. Member
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      02-26-2011 10:49 PM #44

      "This motor originally had a power steering pump on it. Since that is gone the belt for the alt no longer lines up with any other pulleys. Guess I need to find some different pulley(s)."
      "The alternator pulley still eludes me though. I did figure out what is going on with it though. It is driven by the A/C pulley. What is needed is a non a/c alternator pulley. Not so easy to find. "

      Or ,maybe ,create or obtain an A/C &/or P/S idler pulley (#14ish) to fill in the gaps?:

      from
      http://images.google.com/images?hl=e...&aqi=&aql=&oq= .

    10. Member
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      02-26-2011 11:12 PM #45

      "Is there a plastic cover that goes over the pump etc? I believe there is one on the 91 parts car that I bought."
      "Of all the MKII's I've owned/worked on, I've never seen a cover. But that doesn't mean there isn't one."

      IIRC Norm that'd be a 165-201-546,listed but not shown in the catalogue specificly only on PL & 9A 16V engined cars :
      http://www.auto-parts.spb.ru/cat/au/...XTF/AGImO0Fhy1 .

    11. Semi-n00b
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      02-26-2011 11:29 PM #46
      There are proper pulleys for that application. As it turns out, my donor car (1990 Golf Automatic) didn't have power steering. It was a pig to steer unless it was moving, and even then it was no picnic. Much worse than my baywindow, probably in large part to having the engine and transmission right over the front wheels, and a small steering wheel as well.

      If that engine had had power steering, it would have wound up in my wife's 1988 vanagon instead. But she wasn't giving up PS on the vanagon, so it was put in our Bay instead.

      Here are some pics of the pulley set you are looking for:







      Sorry about for the rust and the low-quality phonecam pics.

    12. 02-26-2011 11:35 PM #47
      Oh, there you are. It's about friggin time you said hi!!! I think the idler pulley would
      be a nightmare. I did find a aftermarket pulley at $52+ship and handling. So the plate is
      only on 16v motors? No wonder I've never seen one. I really don't think there is any room for one, at least not with my setup. Pretty tight as is. Thanks for the info Mr. Buggy.
      Looks like I am missing the wire loom from the digifant to the fuse box. Back to the wreckers tomorrow.

    13. 02-26-2011 11:39 PM #48
      westfakia

      Thanks for the hi quality rusty pics. That pulley is in high demand. If you look on the MKII WTB forums there are alot of requests.

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      02-26-2011 11:43 PM #49

      What's the part#(on the silver sticker ) of the alternator you show here:

      westfakia ?,I might be able to narrow down a direct part # application for that pulley.

    15. Semi-n00b
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      02-27-2011 12:06 AM #50
      Here are the numbers from the silver sticker:

      VW P/N 037 903 023P 3AO

      Bosch P/N 9 127 041 200 * 201

      Happy hunting!

    16. 02-27-2011 12:16 AM #51
      lookin good man
      DHP, bringing the Dry Heat or What?!

      http://dhpvw.com/blog/

      pinstripes by el Roy http://www.facebook.com/#!/pages/El-...52145338182434

    17. Member
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      02-27-2011 12:47 AM #52

      "Oh, there you are. It's about friggin time you said hi!!! "
      They don't let me out alot anymore .

      "Bosch P/N 9 127 041 200 * 201 ,I was thinkin' maybe more along the lines of more brand crossapplications like maybe Volvo or marine(sailboat diesel trolling engines) as an alternative place to look:
      http://www.google.com/#sclient=psy&h...ddd8bed91671fa
      http://www.google.com/#sclient=psy&h...ddd8bed91671fa
      just for grins if'n it hadn't been considered before .
      couldn't hoit .

    18. Member Neptuno's Avatar
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      82 Scirocco~Rodolfo~85 Vanagon~El Guapo~
      02-27-2011 10:48 AM #53
      Hi Air,

      I wanted to start by saying: What a great build!!! I have a Vanagon and also a scirocco. The Vanagon is mostly unmolested, but the signs indicate that at some point the WBX will give up the ghost....when that happens inline 4 is the replacement that I wil put in there.

      Builds like yours are great and full on ingenuity.... Well any how, About the the alternator belt let me give you some ideas that occurred to me as resources for your issue. Being with the Scirocco list and the forum here I have encountered some very clever people. Here is something I did when swapping from a 65amp alternator to a 90 amp alternator in the scirocco:
      http://www.vintagewatercooleds.com/t...alternator.htm
      Main idea for you is propping that alt pulley of yours out. A couple of large washers and a shaving to the woodruff (sp) key that holds the pulley inline with the shaft of the alternator should get you closer to aliment.

      Another thing is using the crank pulley from another set up to make things even.....here are some belt set ups:
      http://www.vintagewatercooleds.com/t...elts/belts.htm

      And if all of you have some time for great tips here are Timbos tech notes:
      new: http://www.vintagewatercooleds.com/tech/
      old: http://www.vintagewatercooleds.com/tech/old_index.html

      Good luck with the build!!
      Last edited by Neptuno; 02-27-2011 at 10:51 AM. Reason: funny this is post #53.....why is that important? hehe

    19. Semi-n00b
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      02-27-2011 08:18 PM #54
      Well, "Want" is a subjective term. Mostly I have to use what's handy and fits my budget. And I have lots of sintra available.

      BUT...

      Today I uncovered a local classified ad just offered up a Suzuki fibreglass spare tire cover for a reasonable price. I expect to be picking it up tomorrow. With a bit of rework, it should be just the thing I am looking for.

      Item for sale:


      Artists concept:


      I've been looking at these hanging on the back of RAV4s and CR-Vs for a couple years now and have never been able to lay hands on one. Now it looks like I have that covered.



      Quote Originally Posted by SauerKraut View Post
      As always, some impressive stuff going on there.

      To the guy who wants to use sintra, I'd suggest not using it like that. It's a cheap plastic that isn't intended to withstand prolonged outdoor use and will dry out and eventually become even more brittle and crack from temperature cycles, UV, etc. Even with paint on it, it'll look like crap in a short time. Go with metal or fiberglass.
      Last edited by westfakia; 02-28-2011 at 02:46 PM.

    20. 02-27-2011 09:43 PM #55
      Well after 2 days of parts chasing, I got lucky.






      Last edited by air skooled; 02-27-2011 at 11:59 PM.

    21. Member Jade Wombat's Avatar
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      02-27-2011 09:54 PM #56
      Great stuff, CIS system?

      Just curious, you said you're going to powdercoat the exhaust though, aren't you worried about temperature? Most exhaust go with ceramic coating because of the heat. It doesn't look as cool but does the trick. My bug exhaust was about $60 to do.


    22. Semi-n00b
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      02-27-2011 10:10 PM #57
      Looks like a Digifant engine and fuel pump to me. CIS would require a different cylinder head and pump.

      Quote Originally Posted by Jade Wombat View Post
      Great stuff, CIS system?

    23. Member
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      02-27-2011 10:20 PM #58
      And the search for the pulley comes to a happy ending.Looks like it's lined up nice now.I wonder what,if any at all, effect different pulley size will have on the alternator.

    24. 02-28-2011 12:02 AM #59
      The powder coat that I use is made for exhaust systems. Will handle 1000 degrees.
      System is digifant II. Alternator won't be affected.

    25. 03-01-2011 08:21 PM #60
      Air,

      What's happening? Any progress pictures?

      Keep em coming.

    26. 03-03-2011 09:34 PM #61
      Well I have managed to catch the dreaded gamboo. Sucks being sick. I have managed to get the radiator setup almost finished. It is in place and am currently running hose's and tubing. The wiring is finished with the exception of the o2 sensor and the fans. The fuel lines are all run and the pump turns on. Still need to come up with a way to mount the MAF. Not going to run the air box, just a cone filter. Pics later.

    27. Semi-n00b
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      03-03-2011 11:25 PM #62
      Definitely itching for more pics. Work has me out of town and unable to find garage time for my conversion until the weekend, so I am hoping to live vicariously through your images!

    28. 03-05-2011 06:15 PM #63
      Quick update. Started it today. Runs good and the exhaust is fairly quiet . I still feel like crap. Off to buy some more parts.

    29. Member
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      03-05-2011 07:27 PM #64
      Nice!..time for a video,after ya hit the clinic and get that stuff that ails ya cleared up.Glass of Wild Turkey with a cpl ice cubes you'll be up and running at full speed.

    30. 03-05-2011 10:53 PM #65
      Quote Originally Posted by zzzdanz View Post
      Nice!..time for a video,after ya hit the clinic and get that stuff that ails ya cleared up.Glass of Wild Turkey with a cpl ice cubes you'll be up and running at full speed.
      Done and done.
      It will run better once I set the timing and get it on the street.

      http://www.youtube.com/watch?v=DIyqNN2whNI

    31. Member SauerKraut's Avatar
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      03-06-2011 01:20 AM #66
      Just got back in tonight.....

      **** yea!!
      DCI FOR LIFE
      vansquad - poppin your top, bitch!

      dmiw.

    32. 03-06-2011 07:15 AM #67
      Sounds pretty good. Not too loud. When you get a chance I'd really like to see some pictures of the rad set up. You have done one of the better jobs of documenting the conversion that I have seen on the net. Would be a shame not to see the rest of the steps for those who are curious or either planning to do the same.

      Craig

    33. Semi-n00b
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      03-06-2011 07:32 AM #68
      FWIW I ported my build log into wordpress last night. It'll be a lot easier to make updates now.
      http://www.pottsfamily.ca/wordpress/

      Now to stop messing with computers and crap and find time to get back to working on the bus!

    34. 03-09-2011 11:32 AM #69
      No pictures?

    35. 03-09-2011 03:42 PM #70
      No pics because I'm not finished yet. Still sick. Might be able to work on it today.
      Patience.

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