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

[Norman72]

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

[westfakia]

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:

[VWRedux]

Just browsing around... happened onto your thread... damn... some good looking serious sh*t going on here! Great job!

[SauerKraut]

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.

[air skooled]

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.

[zzzdanz]

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.

[Norman72]

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

[air skooled]

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.

[buggyman]

"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= .

[buggyman]

"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 .

[westfakia]

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.

[air skooled]

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.

[air skooled]

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.

[buggyman]

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.

[westfakia]

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!

[royragtop]

lookin good man

[buggyman]

"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 .

[Neptuno]

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!!

[westfakia]

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.

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.

[air skooled]

Well after 2 days of parts chasing, I got lucky.

[Jade Wombat]

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.

[westfakia]

Looks like a Digifant engine and fuel pump to me. CIS would require a different cylinder head and pump.

Great stuff, CIS system?

[zzzdanz]

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.

[air skooled]

The powder coat that I use is made for exhaust systems. Will handle 1000 degrees.
System is digifant II. Alternator won't be affected.

[Norman72]

Air,

What's happening? Any progress pictures?

Keep em coming.

[air skooled]

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.

[westfakia]

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!

[air skooled]

Quick update. Started it today. Runs good and the exhaust is fairly quiet . I still feel like crap. Off to buy some more parts.

[zzzdanz]

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.

[air skooled]

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

[SauerKraut]

Just got back in tonight.....

**** yea!!

[Norman72]

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

[westfakia]

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!

[Norman72]

No pictures?

[air skooled]

No pics because I'm not finished yet. Still sick. Might be able to work on it today.
Patience.