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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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 Posted: Wed Aug 20, 2014 4:02 pm Post subject: Otter gets a Bostig |
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This is Otter. She's a slightly modified '84 Westy that has taken us faithfully all the way to Yellowstone, The Tetons, and around the amazing Pacific Northwest for the past two years of camping with my young family. She developed a bit of an oil leak, a bit of oil pressure drop, and loss of coolant in various locations enough for me to suspect that she was ready for a transplant. The other day I discovered a crack in the head near a head bolt. I'll be using her for my daily driver for the next few months (4 miles) while prepping and gathering parts for our Bostig conversion. She already received Jaguar big brakes, 16" Passat steel wheels, and Nokian Entyres last month.
While the PNW is rife with Subaru, all are loved to death and have high mileage, and I love the clean look of the Zetec. Ok, I'll admit right now I'm originally from Detroit...
With the amazing help of a fellow Samba member, I bought a group 22b kit, and hoping to complete my RG3 mods to the air box.
The donor motor has 80K which is a bit on the high side, but complete and clean. I'll be doing a cold compression test, and leak down test this week. With any luck this build log will be short and sweet. I do tend to take a lot of pics to document my builds, and hope to do some movies as well.
Last edited by scottychop on Mon Aug 25, 2014 7:45 pm; edited 2 times in total |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32563
Location: Reading Pennsylvania
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levi
Samba Member
Joined: February 11, 2005
Posts: 5522
Location: Las Vegas
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| Posted: Wed Aug 20, 2014 6:44 pm Post subject: |
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One World engine, for our one world.
_________________
One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way
https://youtu.be/cSrL0BXsO40 |
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alnvilma
Samba Member
Joined: March 07, 2002
Posts: 395
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| Posted: Wed Aug 20, 2014 8:13 pm Post subject: |
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scottychop,
When I prepped my 40k Zetech, I used an injector rebuild kit to replace all the O rings, but also the micro-screens. They varnish up like the pintels.
I don't know how much that helped but, mine fired up the first time in 2 seconds and idles perfectly 3000 miles later  Just an FYI |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Wed Aug 20, 2014 9:30 pm Post subject: |
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| Cool. I actually swapped out my rail for one with only 10k on it. Glad to hear yours is running great. |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Fri Aug 22, 2014 6:29 pm Post subject: |
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Packages started arriving today! I was quite paranoid about buying a used kit. The unknowns can be just too much. I printed out a few of the inventory sheets from Bostig's website and went through each box. Everything there with only a few changes from the current documentation, all hardware amount related. The seller through in an air box/maf which was actually a surprise! Still waiting on two of his boxes, a box from the yard with my ECU, a box from Ford, and another RA order. Getting excited!
His kit was actually for a PS vehicle if anyone needs the parts. I have the pump too. |
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SyncroBilly
Samba Member
Joined: June 02, 2014
Posts: 230
Location: New York
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| Posted: Fri Aug 22, 2014 8:06 pm Post subject: |
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| The motor looks pretty clean from the picture. Looking forward to some pics. Congrats! |
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JudoJeff
Samba Member
Joined: May 24, 2013
Posts: 1179
Location: Near Springfield, MA
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| Posted: Sat Aug 23, 2014 5:33 am Post subject: |
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The current Bostig manual, #22,which you most likely downloaded, does have some changes from what work you'll actually do. All are minor. Read the posts on the Bostig website that pertain to doing an install, and all will be enlightened!
Ask me anything, and if I know the answer, I'll tell you. It's much easier than you think, do everything step-by-step, with no thought to what's next.
The engine looks great!
_________________
________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout) |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Sun Aug 24, 2014 4:28 pm Post subject: Progress |
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In between family events today I managed to sneak a half hour worth of work in. Sensors and barbs installed.
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Sun Aug 24, 2014 5:03 pm Post subject: |
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| I've had the HF compression tester for the last two cars I've owned and had no problems with the connections. Well, the deep bore of the spark plugs on these little fords leaves me unable to connect with a threaded boss. I "think" I can use an adaptor or just use the press in kind? Any help here? |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Mon Sep 01, 2014 5:29 pm Post subject: |
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Got a fair bit done today. I ended up swapping heads on the engine after a snapped exhaust bolt AND a snapped extractor. I put on a 2003 head with only 10K on it, new gasket, new head bolts, new timing belt, pulleys, and tensioner.
With the top done I pulled the pan off and cleaned up the old sealant. HCOP should be here soon.
Then tackled the ECU and box.
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SyncroBilly
Samba Member
Joined: June 02, 2014
Posts: 230
Location: New York
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| Posted: Tue Sep 02, 2014 6:44 pm Post subject: |
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Looking good!
Doing the HC oil pan on the engine stand will probably make your life easier. I've read about guys installing it while motor was in place. I heard it was a real PITA. My big fat hands barely fit inside in order to tighten a couple of the bolts. Flipping the motor upside down on the stand probably saved me alot of grief.
Keep the pics coming  |
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zombievws
Samba Member
Joined: July 14, 2012
Posts: 136
Location: greeneville tn
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| Posted: Tue Sep 02, 2014 7:28 pm Post subject: |
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I spoke with jim from bostig today on the phone. guy seems genuwine and very informative. hope to do some business with these kits soon. good luck on your project.
_________________
unique is what we seek, bizarre is what we are. |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Tue Sep 02, 2014 8:31 pm Post subject: |
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Thanks fellas,
It's been a super steep learning curve. I think the biggest advice I can give thus far is to get a GOOD engine from the start and read every post here, and on the Bostig site six times before you start anything. Oh, and 44 inch pounds is NOT the same thing as 44 foot pounds...  |
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turbotransporter
Samba Member
Joined: February 19, 2006
Posts: 459
Location: Bainbridge Island WA
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| Posted: Wed Sep 03, 2014 7:17 am Post subject: |
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Installing the Bostig HCOP upside down on an engine stand is quite a bit easier than doing it with the engine in the van though it can get complicated quickly IF you happen to drop a bolt or nut into the engine... 
If this happens be sure to retrieve it! It may mean you need to remove the pan, clean up the RTV/Right Stuff/Whatever and start over but...
The Bostig Boys are a class act.  |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Fri Sep 05, 2014 4:50 pm Post subject: |
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Pan in, sealant squished. I used the orange stuff cause that's what I had. I also got a neat little surprise in the mail. All the way from the UK.
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SyncroBilly
Samba Member
Joined: June 02, 2014
Posts: 230
Location: New York
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| Posted: Fri Sep 05, 2014 5:11 pm Post subject: |
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| Very cool. Im so far away from getting decals or anything yet. I like that zetec badge. |
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Wed Sep 10, 2014 11:13 pm Post subject: |
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Got a little shop time in this evening. I mounted the alternator, power steering bracket, and got it off the engine stand to work on the adaptor plate. I changed out the CPS and bolted on the adaptor and shims. Pilot bearing went in without a hitch.
Then the flywheel, motor mounts, and cradle. Cleaned the garage and measured just how high I can raise the van. It'll be close…
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scottychop
Samba Member
Joined: January 23, 2013
Posts: 187
Location: Seattle
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| Posted: Fri Sep 12, 2014 9:15 pm Post subject: |
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Well, here's proof you can fit a Vanagon inside a 1940's Seattle war box garage! 8 inch ramps plus garage door trim removal and I have clearance!
and a piece of carpet on top just in case there was some friction. NO, that's not blood. 
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JudoJeff
Samba Member
Joined: May 24, 2013
Posts: 1179
Location: Near Springfield, MA
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| Posted: Sat Sep 13, 2014 6:00 am Post subject: |
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FYI: I put the zetec/tranny on a big piece of cardboard and easily shoved it under the westy with my legs. Then hooked up the engine hoist to put it into position, hydraulic jack under the tranny. inch-by-inch.....
_________________
________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout) |
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