New bay window owner/Watercooled Conversion

Mr. Unpopular

I recently talked my wife into purchasing a bay window as our first bus. We're no stranger to VW's but this is our first type 2. We enjoy camping at VW shows, and we also have a rail buggy we take to the woods a few times a year. Until now, we've tent camped, but are growing tired of that. After hanging out in a friends early bay westy, we decided a westy could work for us fine. Currently it's just my wife and I but we are hoping to try for a baby next year.

So enough about us, onto the bus. I honestly only looked for a week, but as soon as this bus came up on the samba it seemed perfect for us. My wife's favorite color is green, the bus seems in very good shape minus the motor (more on that in a minute), and best of all, it seemed like a very good deal. After a very long and nervous weekend of waiting to get ahold of the seller, I drug my friend and my trailer from north of Tampa to Sarasota (a little over 100 miles) to go and get it. We paid the asking price of $1500 which I think is more than fair, especially considering how the bays are jumping in popularity around Florida.

The bus is a 78 Westy. It really doesn't have much rust. Around the windshield (mainly the bottom), bottom of the nose at the floors (not bad), the floors at the step in front of the front tire, and a couple of very small spots on the cargo floor (the worst is from the leaking vent window in the back on the drivers side, but it still isn't bad).

The interior is in very good shape, with only the cooler cabinet being water damaged (from that leaky window). It was included so I can use it as a template if we decide to do that. All of the latches are in place and work.

The rock and roll bed and rear bed cushion look brand new, the front seats are in good shape with some wear on the covers. The top cushion on the roof looks brand new, but it's missing the extension pieces that go in the opening. It's missing the childs cot, but came with all curtains (even the wrap around for the windshield and front windows) as well as the mosquito net for the rear hatch.

OK, so our plans are to preserve the interior and the body and drive the heck out of it.

Mechanically, this is where I predict some drama. I plan to swap a Chevy Ecotec 2.2 for an engine. I have a motor, computer and harness in my garage that I was saving for our next rail buggy. I intend to mount a radiator between the frame rails.

I also plan to build a rear disk brake setup. I hate drum brakes, and as I said, I intend to pull our rail buggy with it on a trailer, so I'd love as much braking as possible.

Here are the pics from the ad. I'll take some better pics of the rust and document my progress.

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

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chabanais · Samba Member Joined: July 27, 2002 Posts: 4866

Nice Bus too bad you're not staying with the Type IV.
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Mr. Unpopular · Posted: Wed Jun 15, 2011 8:41 pm Post subject:

Well, between wanting to drive all over Florida camping in it, and letting my wife drive it around town, I just can't justify keeping it air cooled.

I know a TIV can be made reliable and powerful and all that, but I've got less into the motor, computer, harness and alternator than I'd have in a set of main bearings for the TIV. And with all of the horror stories about shoddy parts and machining lately, it's a no brainer to me.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

chabanais · Samba Member Joined: July 27, 2002 Posts: 4866

Post pics and good luck with your build.
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phoneguy · Posted: Thu Jun 16, 2011 5:16 am Post subject:

Should be an interesting build to say the least,start a thread on it !
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jonblack · Posted: Thu Jun 16, 2011 5:57 am Post subject:

I'm watching this thread, as I have interest in swapping a different engine into my bus. I have always been a Honda Civic guy. Would love to put a simple D16 engine into my bus but don't know how to get around the fact the Honda engine rotates in the opposite direction as the VW 1600.

Anyway, good luck with your build, I will be interested to see how it progresses.

jonblack
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Mr. Unpopular · Posted: Thu Jun 16, 2011 6:05 am Post subject:

The newer Honda's spin the right way. I have friends with Honda's in their rail buggies and those motors work very well. One has a J35 V6 from an Odyssey, one has a F22 from an S2000, and another recently purchased a K24 from an RSX for his race car.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

Jody '71 · Posted: Thu Jun 16, 2011 6:25 am Post subject:

I helped a good friend of mine do the water cooled engine swap. He used the old Toyota 4 cyl 1.8 which were pretty good engines back in the 80's. Biggest hurdles where making/creating the rear engine hanger to fit the Bus ('76 Riviera), creating the exhaust and setting up the radiator. We never got around to figure out a heating system for the interior. Don't forget you need the adapter stuff for the engine to transmission. Additionally, I hope you're good at electrical wiring!
It was a major undertaking and I learned how to weld. I don't mean to be dis-persuasive, but it is a lot of work. You're gonna need Bus rated tires too, the ones on there now are passsenger car tires if I'm not mistaken.
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Mr. Unpopular · Posted: Thu Jun 16, 2011 6:27 am Post subject:

I've got quite a bit of experience welding (I built my rail buggy) and have done an Ecotec swap in a rail buggy for a friend, including stripping down the wiring harness. The fab work and electrical work don't scare me, that's what I'm good at Very Happy

I'll post pictures along the way of everything I do.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

Jody '71 · Posted: Thu Jun 16, 2011 6:36 am Post subject:

Cool! can't wait to see your pics!!!! Have fun!!!!
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'66 Beetle
2011 Hyundai Elantra Touring

Mr. Unpopular · Posted: Thu Jun 16, 2011 6:38 am Post subject:

As far as the tires, I will definitely swap to truck rated. This is a heavy camper, we take alot of gear to the woods, and towing a buggy. No chances will be taken there.

The question I now have is should I upgrade to 15" rims or keep the 14's. I'd like to eventually lower the bus a couple of inches so my wife can get in and out of the front seats easier, and it seems most of the 15" truck tires are bigger than stock.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

Jody '71 · Posted: Thu Jun 16, 2011 7:08 am Post subject:

IMO I would stay with 14's. If you opt for 15's then do a tire size calculator that will keep your speedometer in the groove. Lowering the Bus is your option, that involves quite a bit of work as well. There was a topic I think about a year ago concerning how people get into the front seats, everyone has their own method.
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'66 Beetle
2011 Hyundai Elantra Touring

ned · Posted: Thu Jun 16, 2011 7:17 am Post subject:

Sounds like a great project. The up side of going to 15`s is you will have more tire options.

Mr. Unpopular · Posted: Thu Jun 16, 2011 7:19 am Post subject:

Not only more options, but more likely to get a replacement if I have a tire blow out in the middle of nowhere. I will have a spare either way, but it's nice to know another tire isn't a day away.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

ned · Posted: Thu Jun 16, 2011 7:22 am Post subject:

You got that right. It seems that 14 is now a special order item.

Krautski · Posted: Thu Jun 16, 2011 7:26 am Post subject:

With your powertrain plan, you'll live up to your screenname around here. Cool

If you do it right, hardly anyone will even be able to tell until you hitch up your big trailer or pass them.
I have yet to find your average "hey nice bus" person able to pick up that its not aircooled.

PM me if you ever need pictures or ideas of "where/how should I put ___" along the way.
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Mr. Unpopular · Posted: Thu Jun 16, 2011 7:32 am Post subject:

Thanks Krautski! I've pretty much decided that under the bus is the best place for the radiator mainly because it will look stock. I need to make sure wherever I choose works well because towing in Florida in the summer will definitely test a system.

My wife and I can't wait to get started! We're hoping to have it drivable for the Nough Dough Bus Show next year as that's a great event with awesome camping.
_________________
"In any racing engine, the nearer you are to it disintegrating, the better it's performance will be"
-Keith Duckworth, creator of the Ford/Cosworth DFV

kruton · Posted: Thu Jun 16, 2011 4:57 pm Post subject:

sweet find neighbor - i live in the space coast and i recently just got my first bus too. I have been finishing the restore and just waiting for my motor to get rebuilt then ill be on the road. I am very interested to see your progress on the engine conversion. Good Luck!
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chazz79 · Posted: Wed Jun 22, 2011 7:56 pm Post subject:

You have to use 15 inch wheels to get your gearing within reasonable range. I have 205/75/15 tires that are @2 inches taller than stock. I also had to get a 6 rib trans to get the taller gearing. With these changes my highway rpm is @3500 at 70mph. With the stock tires and a 3 rib trans I'd been at 4500, and no watercooled engine will live long running like that for hours on end. My whole install is pretty low profile and 100% reversable. The ecotec is a pretty good option but doesn't make a ton of low end torque stock. Most were coupled to automatics so no one knew of that flaw. If you ever drove a manual trans cavi you'd know they're lame down low. They do respond well to turbos though.

You'll love your bus more when you're done! My bus has a full camper set up and gets close to 20mpg. I hope to improve that by doing a efi swap soon enough.
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Mr. Unpopular · Posted: Wed Jun 22, 2011 8:03 pm Post subject:


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