My Bostig Ztec conversion

Zero419 · Posted: Sat Apr 07, 2012 4:52 am Post subject:

what kind of problems did you have?

Thanks for the complements, I kinda thought I might be getting annoying in a facebook kinda way. (no I don't use facebook) Shocked

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1987 Westy Auto Bostig 2.0 Ztec

scottf3334 · Posted: Sat Apr 07, 2012 7:10 am Post subject:

I'm following your thread too. Cool

For me the most time consuming thing was figuring out exactly which part to use. I'm a perfectionist and figuring out things like which bolt should I use or why did they include 3 washers. Do they want one under the bolt head and 2 under the nut or should I be mixing the big washers with the small washers.

Things like that. I'd read then reread then try to find it in the video and zoom in so I could see. So that was really time consuming.

In the end, everything went together, just like common sense would dictate.

I just wanted it to be perfect, it's a lot of money and my mom is going all over the country in it.

I'm totally confident in our Bostig conversion now. If you have any questions, post them. There are many that have done the conversion and it will make it easier for others to do
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84 Westy
78 Super vert
87 Westy Zetec

Kopasz · Posted: Sat Apr 07, 2012 7:47 am Post subject:

I didn't really have problems, just complications I suppose. My wasserboxer was blown due to a broken coolant expansion tank which led to a cracked cylinder sleeve. The van was immobile and stuck in my driveway.

The van sat like that for several months while I contemplated what to do: sell it and try to get something else; repair the wbx; or do a conversion. After some research and discussions with my wife, we decided on the Bostig.

I started thinking it would be a quick process, but I only had evenings and a couple of weekends to complete the job because my in-laws were coming to visit. They were coming with their new RV and the van was stuck in the driveway, which is where they needed to park. I also still had to pick up the crate engine from Seattle and wait for some miscellaneous shipments from Bostig. I got my kit from Brady and Jim outside of the usual group buys and they accommodated me with some extra parts they had on the shelves and were able to throw a kit together for me.

I was on an unrealistic time crunch and had very limited mechanical knowledge. I also did not have everything I needed when I started, which caused me to frantically run around town looking for the right parts, tools, etc. My very relaxed and unreliable friend Max was helping me too, which added to the time, decreased my patience, and was distracting overall; I gotta say we drank a good amount of great local beer though!

To add to the difficulty, my driveway was a mixture of large busted up concrete pieces, gravel, roots, and dirt. One problem that caused was that the aftermarket motor months from Rock Auto broke when I lowered the jack after bolting the engine into the van. The driveway was so uneven and unstable that the weight of the engine combined with van cracked the chunk of concrete the jack was sitting on, thereby dropping the van onto the motor mounts on the cradle. I heard a strange crack, but couldn't see or feel any cracks or tears on the mounts or cradle, so I kept on trucking. When I started up the van, the noise and volume inside the van was unbearable. I trouble shot this with Brady and Jim for months before just deciding to live with it. That was about 2 yrs ago.

Bostig has since discovered that the aftermarket motor mounts were not always the best quality. From what I could tell, it seemed like I had the good aftermarket motor mounts, but I am convinced that they were compromised when the jack dropped the engine down on them. I switched my mounts out a few weeks ago for the OEM Ford mounts and it's made a world of difference. The new mounts, combined with the extensive sound deadening I did and muffler/glass pack combo I put in make the van sound truly awesome.

The conversion was fun, I learned a lot, and I would definitely do it again, but I would plan accordingly and make sure I had all necessary tools, parts, etc. before starting.
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adam

'87 Wolfsburg Weekender, Bostig Zetec

The rehabilitation of my Van can be found here: http://www.thesamba.com/vw/forum/viewtopic.php?p=5949024#5949024

Zero419 · Posted: Sat Apr 07, 2012 7:56 am Post subject:

I'm kind of in the same boat.
I ordered in between group buys, but they had a kit put together. Anybody can buy between, as long as they have one available. you miss out on the 10% off, but it's worth it to me to get the van going sooner. We got 5% off because my wife (her van) is a civil servant.

I keep on finding parts that I need that I didn't plan on. gaskets, pulleys, the total keeps going up. I might end up 300 or so over my earlier cost breakdown. I have a new order in to rock auto or a local flaps every day. I'm starting to lose track!

Like you, my van is parked on gravel/dirt. I wish I had a garage.

I spent 3 grand rebuilding my 2.1. I replaced everything internally and externally hoping it would last for years to come. A reground cam and possibly bad lifters caused a failure. I almost rebuilt it again, but we decided to go Bostig. When this is all over, I hope to sell the tons of parts I have and recoup 1000 bucks or so.
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1987 Westy Auto Bostig 2.0 Ztec

Zero419 · Posted: Sat Apr 07, 2012 8:04 am Post subject:

austinindian · Posted: Sat Apr 07, 2012 10:01 am Post subject:

I'm following you closely, too. Smile

Just started my Bostig g-19 experience. I'll get the old van running cross country at some point.

Saw Dave B on this thread. Howdy, Dave!

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Zero419 · Posted: Sat Apr 07, 2012 10:38 am Post subject:

I just installed the flexplate and the adapter. Did the coolant housing and all the stuff that bolts to that (no hoses)
What? that's it? kids are still napping!
Guess I'll have a beer and chill 'till they get up.
Does this mean I have to be sociable this weekend?
Take the dogs to the pond? Have a camp fire with some buddies by the pit?
Well I guess I can run the fuel line, maybe wire the "low oil" light to the dash, install the new TC seal.
Eh maybe tomorrow, maybe Monday. I think I'll slow down if I can, not really my style, but I gotta make time for life.

More boxes are due Monday....
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1987 Westy Auto Bostig 2.0 Ztec

Zero419 · Posted: Sat Apr 07, 2012 10:56 am Post subject:

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1987 Westy Auto Bostig 2.0 Ztec

Brungeman · Posted: Sat Apr 07, 2012 7:19 pm Post subject:

Nirav, Hello my friend, looks like you are getting in deep with the motor search!

Michael, you are welcome, and man that looks great! Making tons of progress, you are really moving! DON'T slow down!!! but if you don't have the MIL line in the kits that you have... I wouldn't run the low oil light yet. The MIL wire and the Oil light would most likely run the same route up the drivers side frame rail... OH and the throttle cable will also take that route. If you have an electrician's tape, that would help a bunch when chasing the wires.

keep on rockin!
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87 multivan
84 transporter for sale
86 scirocco RIP
71 Baywindow RIP
1972 Super RIP
1969 Bug RIP
1974 Super RIP

ipclark · Posted: Sat Apr 07, 2012 7:52 pm Post subject:

I would also consider routing with the oil level wire, the MIL , tach and and one spare wire for future use. Much easier to run them as a bundle.
Today I had a failure of the drive belt Tensioner Pully, what a noise! That is about the only part I did not replace. Take note!

Image may have been reduced in size. Click image to view fullscreen.

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1984 VW Westfalia Bostig Zetec Powered
Daily Driver 2010 VW Golf Wagon TDI, DSG

ipclark · Posted: Sat Apr 07, 2012 9:07 pm Post subject:

Forget my mention of the tach wire. I have an 84 with an clock instead of a tach. I upgraded the cluster to one with a tach, so I had to run a wire. You have no such problem.
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1984 VW Westfalia Bostig Zetec Powered
Daily Driver 2010 VW Golf Wagon TDI, DSG

thatvwbusguy · Posted: Sat Apr 07, 2012 9:44 pm Post subject:

To avoid the hassle of running multiple wires and bundling them together with zip ties or split loom you could use a multi-conductor trailer cable. They are available in many different gauges and strand setups. Here is a link to one that I think would work great for any engine conversion:

http://www.delcity.net/store/Trailer-Cable/p_366.h_185060.a_1.t_1
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Jay Brown
'85 Zetec Westfalia
Newmarket, NH
VANAGON HEADLIGHT RELAYS & HARD START RELAYS

Zero419 · Posted: Sun Apr 08, 2012 5:09 am Post subject:

Brungeman · Posted: Sun Apr 08, 2012 5:48 am Post subject:

ipclark · Posted: Sun Apr 08, 2012 6:06 am Post subject:

I used this wonderful guide written by Jim Thompson.
http://www.oldvolkshome.com/late_van_cluster_install.pdf
It explains everything. I used a cluster from an 85 Wolfsburg. I was able to swap out the speedo unit as for my application they were identical. I did have to run a wire, but as you have a latter model (87?), it may be different.
Many thanks to him
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1984 VW Westfalia Bostig Zetec Powered
Daily Driver 2010 VW Golf Wagon TDI, DSG

bugger101 · Posted: Sun Apr 08, 2012 9:51 am Post subject:

I hope everything goes well for you Very Happy

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75 west deluxe http://www.thesamba.com/vw/forum/viewtopic.php?p=5270450#5270450

2010 ford focus
1949 ford f-1
2006 Lincoln navigator

automotive student
ford line tech

Zero419 · Posted: Mon Apr 09, 2012 6:45 am Post subject:

The written directions have an order different then the videos.
The directions say to install the adapter, cooling block, mounting kit, then stuff it in the van, then, intake, coolant hoses, fuel rail stuff.

In the video’s it looks like most everything is done on the engine prior to install to the van. It looks a lot easier to get to stuff. I’m assuming it was done out of the van for the video.

What did the experienced do?
Thanks for the input.
Packages expected today, going to hit it hard, may take off work tomorrow.
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1987 Westy Auto Bostig 2.0 Ztec

Brungeman · Posted: Mon Apr 09, 2012 6:53 am Post subject:

I did almost everything on the motor out of the van. Since I haven't done it any other way I cant say if it is easier because I have no point of ref… but I will say doing the conversion the way I did, the parts I assembled out of the engine and having it right in front of you on the stand was easier than stretching into the engine bay for the parts I still needed to do.

today will be sweet… I got all the boxes for my install 2 days before my birthday. I know the Bostig crew couldn't have known it, but it was a great birthday gift! Wink

_________________
87 multivan
84 transporter for sale
86 scirocco RIP
71 Baywindow RIP
1972 Super RIP
1969 Bug RIP
1974 Super RIP

Zero419 · Posted: Mon Apr 09, 2012 7:36 am Post subject:

Happy soon to be B-day!
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1987 Westy Auto Bostig 2.0 Ztec

buildyourown · Posted: Mon Apr 09, 2012 1:34 pm Post subject:

I did stuff way out of order. I read all the directions and then made my own decisions about what I wanted to do when.
It sounds ballsy, but I do this sort of planning all the time for work. I knew it could bite me but worst case I have to take some stuff apart.
I didn't see any advantage to doing the coolant hoses before the engine goes in. Just more stuff to snag.
I also did the exhaust dead last. Didn't want to cut my head open on a tail pipe. Already been there.

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My Bostig Ztec conversion
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