Bostig RG6 and beyond

[torchmonkey]

Anyone else's exhaust pop upon deceleration like mine?

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1983 1/2 Westfalia

[Franagon]

Mine does. Not sure that there is anything that can be done about it. I am using the different Walker muffler. I might even get some occasional popping at highway speeds, under minimal load of the engine. Under acceleration, all seems good. As you probably see, it is really hard to get good audio of it. I am guessing that it has to do with the exhaust system being so short? Don't see many vehicles that have the header, cat, then muffler with literally no piping in between. If anyone else can chime in, I would sure like to get some others thoughts on it. Just giving my experience so far, with few miles on the conversion.
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84 Westy Wolfsburg Manual - RG6 Bostig

[torchmonkey]

I did discover a very slight leak at the clamp but I doubt that is what's causing it to sound that way.
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1983 1/2 Westfalia

[Guybrush]

Regarding the accelerator cable, I just installed mine. This is an 86 manual, 2WD, I'm not sure if there are differences between the years, and the Bostig install is RG7.

I installed the cable with a curve above the engine as in the Bostig photo then went straight out below the "firewall", then down to the double hole through the frame, and followed the exact same path as the original VW cable, through the tunnel above the fuel tank, and straight into the front bracket.

The housing was about 4 inches too long for the front bracket at this point, so I went back under the van in the middle, and just pulled the cable gently towards the driver side in an arc, and zip-tied it to the frame in a couple spots there, and that made it just the right length.

I used bits of fuel hose and zip ties to attach it in several spots, to prevent chafing and moving around too much.

I also didn't bother bending the rear tab out front, as recommended in the doc, as the cable went through both tabs just fine.

once at the connection to the pedal linkage, I made sure the pedal was kept all the way up, pulled the linkage towards the back and pulled the cable tight into it by hand.

If you are by yourself, you can use your phone camera to check for operation of the throttle lever when depressing the pedal:


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[jimf909]

[Reck]

[EDIT; This post originally detailed a problem that I resolved quickly. It was so unique to my car I think it has little to help others. But since I can't delete it, I'll rewrite it in a way that could possibly help someone else.]


I encountered a problem at a very late stage in the conversion. One of my last jobs was to run the MIL wire. I needed to find an always-on spade in the fuse box so, for the first time since I started, I connected the battery. Nothing happened, which was at first a relief (no sparks). But when I turned the ignition on, nothing at all happened; no lights in the dashboard, no current anywhere that I could find in the fuse box. Also, no dome light, no headlights, no wipers.

Conclusion below...
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'84 Westy 2wd, TBD, Bostig RG4 completed 9/16.

[JudoJeff]

In your distribution box, upper right hand top, you have a Bostig wire connected. Where did you connect the other end? Should be on the starter post.

You also have the red and red/white wires that go to the ignition switch on the steering column. Did you forget those when you moved the battery?

The power wire to your fuse box, what's it connected to? If left dangling in space, that would explain a lot.

Hope this helps.
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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)

[Bassyaks]

No, decal popping if the mixture is correct and the exhaust is sealed. If you use a different muffler than what is recommended it may have lower back pressure. But if the kit is installed correctly, there should be NO popping.

[Reck]

[Gary17]

Can someone with the hcop experience tell me how to change the orientation for the dipstick. Nothing I do seems to move it away from the pick up tube.

thanks

[Guybrush]

I didn't touch the dipstick at all during my HCOP install, and that is not mentioned in the doc. You should probably contact Jim for advice.

[Gary17]

Thanks Guybrush.

[torchmonkey]

[Guybrush]

Speaking of muffler, I have the 17904 and I like the clearance it gives from the A/C compressor, but it is very loud.

[jimf909]

[Guybrush]

I'm not comparing as I never installed the original one, it's still in the box. I was thinking of selling it since it's unused. I was worried about the muffler being too close to the A/C compressor and lines and when I read about the 17904 option, I bought it as it was much cheaper. Cut a clearance notch in the rear valence for the tip (my van is not the prettiest one around so that's not a big deal).

One thing I don't like is that the curved portion of the cat doesn't end up pointing straight back, and setting up the muffler to be mostly straight back (vertically in particular) seems to put a strain on the flex connection.

I think it's sealing well at the clamp, and I used the Walker sealing compound. The loudness (deep throaty sound, not unappealing, but can be heard and felt inside the van, which is the problem for me) can be heard directly out of the tip, not near the connection.

I might bring the other exhaust up to it to check the clearance and install it to see if it's better noise wise. At first I couldn't really tell since I ended up having large cracks in the exhaust manifold, and that part was even louder.

I have the skid plate installed and I'm planning to fab something to attach to it and protect the A/C pulley, as well as act as a heat shield between exhaust and compressor/lines.

[kourt]

I have used both the stock Bostig muffler and the 17904 and they are not noticeably different in sound or loudness.

kourt

[Guybrush]

So they are both just loud?

[kourt]

It is true that I have had conversations with both my brother and my wife, who have witnessed my arrival in the van on several occasions, and both have said that when I turn the corner of the street, about 150 feet away from them, that they hear the van coming with its distinct exhaust note.

However, I was driving a friend the other day and he has a Subaru conversion. He said my van was quieter than his. We were doing 70 mph on country roads.

I would not call it loud at all, and my hearing is sensitive. It is distinct and noticeable at certain RPMs, but loud is not how I would describe it.

Also, "loud" can be different things. Loud to the interior passengers of the van, or exterior observers? How much sound deadening is there in the van? Is there a tintop, poptop, or some other top? All these circumstances are different.

It's impossible (and a waste of time) to try to qualify sounds on an internet forum.

kourt

[Guybrush]

At idle, with the van open, standing near the back, or out front, it is loud as in loud deep bass, closer to a motorcycle than a car (except with no puttering). Louder than the WBX setup was, louder than my old Volvo, or any car I've ever owned. It has nothing to do with sound deadening at this point. Just a comment on the amount of noise that comes out of the muffler at the back.