Project: Resurrection (Image heavy)

RatCamper · Last edited by RatCamper on Thu Jun 09, 2011 10:39 pm; edited 1 time in total

G'day. For ages I have been meaning to make a proper project thread here. I have a couple of other elsewhere. One I won't link to because of its rambling nature and abundance of expletives, and the other because of irrelevance.

I had a sort-of thread going but because of its depressing beginning, at least for me I abandoned it. It can be viewed here. http://www.thesamba.com/vw/forum/viewtopic.php?t=428549

A brief summary:

I have owned this bay since about 1999 when I purchased it from a friend for about $200 in need of a lot of attention. The auto transmission had issues, the steering had 1/2 turn of free play (I'm not making that up), and various assorted and amazing gremlins.

It started life as a walkthrough panel with an 1800 dual carb type 4.

Sometime after manufacture, judging by the quality of work I'd say very shortly after, it was converted to a camper by Land Cruisers Australia. Like every other LCA VW camper found (<10) it was gutted because the interior rotted and fell apart. So the only remnants of the camper conversion are the folding bed, the 12v fluoro light and the shore power. And the pop top of course.

Shortly after purchase it was converted to manual with a 002 because the transmission was shot and I had a daily mountainous commute. I probably put between 70000 and 100000 km on it like that. Afterward because of numerous issues it was unregistered a couple of times.

In 2003 it was resurrected for an interstate move. We did this with a trailer. It died in 2004 on a flat road at a modest sped near home with multiple internal engine issues.

Let's skip to about 2010. I spent a lot of time and money on the motor in the interim and it just never quite worked right.
Mid last year i snapped after buying a set of "good heads" from an old ACVW mechanic that were rubbish and bought a "complete" Subaru engine conversion.

This thread is intended to be Bay-centric rather than motor related. that is one reason for starting it. The motor is however an important parts so I'll mention it.

The motor is a Subaru EA81. A 1.8L OHV four cylinder boxer with single port heads. New it output 75bhp. It also revs roughly the same as a type 4. It is attached using an engine bellhousing replacement with a VW 4 stud pattern. It uses the moustache bar from a 1600n t2b with a couple of metal tabs welded on which attach to the Subaru engine mount holes next to the sump.
Currently the motor has the Holley Economizer, GT40 coil and Magnecor spark plug leads from the type 4 on it.
The motor is similar enough that it went from being on the ground to being tested in a few hours.

My goal is resurrection. Restoration is impractical and probably impossible as there is no clear restore point. Also at least one other straighter bay would have to be sacrificed to make it happen.

I recently have reason to push getting it into usable condition ASAP, so it is getting more resources dumped into it than normal.

Here's a couple of shots from last year. It hasn't changed much visually except the exhaust has moved and the rear bumper is currently off. The tarp is also gone. The back window also has more stickers and a new rubber after a lengthy session of lip and frame rust repair with a MIG.

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More to come later.

edit: Somehow I posted an interior pic instead. It gives an idea what's there so I'll leave it. Here's the pic I meant to post:
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_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

RatCamper · Posted: Tue Jun 07, 2011 1:52 am Post subject:

I made an order with CB for the damaged brake line and one of those rhino shift couplers today. Any idea how long int'l shipping takes them? Compared to buying locally their prices are play money so it's all good. I can finally fix the brakes! They weren't broken but a ticking timebomb.

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you can see where the hand brake cable is rubbing on the brake line. I'm surprised it holds fluid. There's a nice groove worn in. the reason that happened is that is an LHD MC. Apparently stocks of RHD MCs ran out a loooong time ago so LHD ones had to be fitted when a replacement was needed.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

72 Bus · Posted: Tue Jun 07, 2011 2:11 pm Post subject:

I like the color setup looks good

RatCamper · Posted: Tue Jun 07, 2011 3:23 pm Post subject:

RatCamper · Posted: Tue Jun 07, 2011 3:30 pm Post subject:

While I'm here. Some miscellaneous photos.

The pop top and plywood base.
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Mercedes Benz Vito wheels may fit but the offset is totally wrong. Failure Sad

If you see a set, don't waste your money.

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Before the black.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

dlrecord · Posted: Tue Jun 07, 2011 6:23 pm Post subject:

Hey Ratcamper,

Great to see your thread! I'm looking forward to more of the story with some good photos to compliment. Get that conversion done and enjoy the bay on the road. We'll provide any encouragement you need!
_________________
1979 Westfalia Campmobile Deluxe
2.0L EFI, 090 auto transmission

-----------------------------------------
Subaru 2.2L conversion project
http://1979vwconversion.blogspot.com/2010/09/start.html

RatCamper · Posted: Thu Jun 09, 2011 12:18 am Post subject:

dlrecord · Posted: Thu Jun 09, 2011 6:25 am Post subject:

I'm looking forward to seeing your set up. I have an early vanagon rear heater under my rear bench but it isn't hooked up yet; I haven't figured out the mounting system yet. Post pics when you can.
_________________
1979 Westfalia Campmobile Deluxe
2.0L EFI, 090 auto transmission

-----------------------------------------
Subaru 2.2L conversion project
http://1979vwconversion.blogspot.com/2010/09/start.html

TomWesty · Posted: Thu Jun 09, 2011 4:31 pm Post subject:

Don't know how to tell you this Rat, but there's a Tasmanian devil loose in your camper...... Smile

_________________
If you haven't bled on them, you haven't worked on them.

RatCamper · Posted: Thu Jun 09, 2011 11:33 pm Post subject:

Yeah, that tassie devil, always making a mess in there ehe heheh Cool

dlrecord. This one is for you.
I'll just add I looked under there today and there was a sign of a very slow leak. Either from the hose to core connection or from the core itself. I tightened everything and will give it a while to settle in before I go ripping things apart again.

Today, apart from actually mounting the heater I finished it.
As with most good ideas I have, it came to me in my sleep. Reuse the booster fan relay to run the heater fan. The beauty of it is that I only need to run one short wire and don't even need a switch!
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There's the blower relay with what I think is the thermo fan relay next to it. Edit: no, that's the dual battery one ...maybe.

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Here's where the heater is situated. As you can see I'm not done. The ply will probably covered in the carpet from the boot/trunk of the Magna. No point in putting the speaker back.
The heater hole is cut further up because the heater will go up when it is mounted / the camper floor is made and installed.
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Here's the plumbing:

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Elbows near heater core.
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From elbows looking back.
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The rest of the plumbing going back to the adapters and bigger hose at the motor.

Everything seems to work. As a bonus because I used the OE relay for the heater the fan only comes on when the motor is running and the alternator light is not lit.

My suspected vacuum leak wasn't. The weather is getting colder and the accelerator cable was a little tight. I guess mild steel expands slightly more than stainless in heat. Anyway I gave it a mm or two of slack and the idling issue disappeared. It's still far too rich over about 2000rpm, but that's something for a later date.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

RatCamper · Posted: Fri Jun 10, 2011 4:36 pm Post subject:

Does anyone know where on the internet the nice RPM based chart and write up for Weber progressives lives?

If I could I swear I'd have one of those Weber books, but Amazon + Australia = Sad

Also it's hard finding it for under $100, so yeah. I have a pretty good idea, I just need to figure out which is over jetted.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

Lionhart94010 · Posted: Fri Jun 10, 2011 5:04 pm Post subject:

I do not know if the URL below will help, but it’s a great resource for Progressives… could you elaborate on what an “RPM based chart” is, jetting chart?

http://www.thesamba.com/vw/forum/viewtopic.php?t=386388
_________________
Current VWs 71 T2 Westy SO-72/6(Miami), 71 Crew Cab, 72 KG GT;0) 12 JSW TDI
Other owned VW’s 59, 68 1500s, 69 & 71 Bug’s; 72 & 73 S-Bug’s; 67 Westy, 67 Deluxe, Other 71 DC
VW technical information sights
thesamba - www.ratwell.com - www.shoptalkforums.com/ - www.vw-resource.com - http://www.type2.com/
http://bobhooversblog.blogspot.com/ - www.aircooled.net/gnrlsite/resource/articles.htm

RatCamper · Posted: Fri Jun 10, 2011 5:12 pm Post subject:

RatCamper · Posted: Sun Jun 19, 2011 4:13 pm Post subject:

I've been hard at work getting nowhere as usual.

No pretty pictures but I did get some of my tuning problems figured out. The wildcard was a charcoal canister purge valve that was full of charcoal and a shimmed power valve. Once I deal with these it's all a lot more reasonable. I need to grab a new spark plug though as one of them has definitely had enough rich / lean abuse and is intermittent.

I discovered that one of the tops of one of the floor corrugations near the back seat was as soft as cheese. Not sure what I can do about that. My guess is that long ago when it had a false floor, it absorbed moisture and rusted the top of the corrugation. When the false camper floor was removed the damage was found and covered. How on earth do I fix that? It's not like I have access to a small chunk of corrugated type 2 floor. If it is just the top (wishful thinking) I guess I could just butt weld in a bit of flat steel.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

RatCamper · Posted: Thu Jul 07, 2011 1:32 am Post subject:

More carburettor problems, badly smoking exhaust now this:
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I'm really having a motivational failure here. Incidentally how does this sound for a bus name; Moby.

edit: 10 non-redeemable samba points to the person that sees the problem first.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

jeffsbugs · Posted: Thu Jul 07, 2011 9:47 am Post subject:

RatCamper · Posted: Thu Jul 07, 2011 3:30 pm Post subject:

AB westy nut · Posted: Thu Jul 07, 2011 3:47 pm Post subject:

RatCamper · Posted: Thu Jul 07, 2011 4:15 pm Post subject:

RatCamper · Posted: Thu Jul 07, 2011 5:12 pm Post subject:

Might as well say. You see that lip? you shouldn't. Yeah that's right. The bottom of the cap melted. No there was no fire. No, nothing else is damaged in the vicinity. Yes I'm worried.
_________________
Vehicle: 1975 Special order delivery walkthrough panel based pop-top camper (LCA / Sunliner). Motor: Nippon 1.8L Single port Wasserboxer, Transmission: 3 rib 002.

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Project: Resurrection (Image heavy)
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