A Black & Blue Su-BUS-aroo Build Thread...

Stuartzickefoose · Posted: Mon Jul 14, 2014 11:53 pm Post subject:

ill take that motor i think...i wish i was closer...
_________________
Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

Nepenthe88 · Posted: Tue Jul 15, 2014 12:29 pm Post subject:

Nepenthe88 · Posted: Tue Jul 15, 2014 1:13 pm Post subject:

Ugh... I guess I'm still fighting air pockets. I jacked the a$$ end of the bus up ran her for a minute or two and free'd a big ol pocket of air. I'm guessing they're coming from the heater core lines since they're such a long run-- I'm somewhere around 26-27 feet worth I estimate.

At least she sounds amazing when she's running. Super smooth... until I ran out of gas. Sigh. Gas can's empty too. Guess I'm done for the day.
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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
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Stuartzickefoose · Posted: Tue Jul 15, 2014 1:57 pm Post subject:

Im almost out of gas too...and no income right now makes it tough to go fill it up Sad

_________________
Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

Stuartzickefoose · Posted: Tue Jul 15, 2014 1:58 pm Post subject:

To test your theory, bypass the heatercore temporarily with a short loop, and get the system bled. If it still overheats, you have another issue. If not, you know for sure where the issue is.
_________________
Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

GeorgeL · Samba Member Joined: January 16, 2006 Posts: 7346

And put a bleed valve at the high point of the heater system. If the heater loop is long and above the engine it will just continue to unprime the pump as long as there is air in the loop.

You might also have a small leak that is letting air in but not allowing coolant to escape. Maddening to find.

Nepenthe88 · Posted: Thu Jul 17, 2014 3:57 pm Post subject:

So.... Today I:
-- cut out the rear window and re-installed it with a new seal. The old one was dry, cracked and leaky.
--Finished installation of a new set of CV boots
--Re-installed the fuel filler neck to the gas tank as it was venting fumes. Why on earth couldn't VW line up the tube with the tank?! Silliness!!
--Tightened the hosebarb in the bottom of the tank as there was the tiniest bit of gasoline wetness down there.
--Re-bled the bus and ran it for 20 min or so.

This time... my temps never went above 205-210ish AND i FINALLY got hot water to flow up to the heater core!! YES!!! Seems my entire issue was a poorly bled system. I shut it off after 20 min and waited for the system to cool down so I could see if it needed any additional coolant. I had to pour in another 2 ounces or so. I'm still not fully confident I've gotten all the air out. I'll take her for a little drive on Monday (I work the next 3 days or I'd do it sooner) and check coolant levels and temps. The small-ish heater lines seem to be the issue as they trap too much air for the pump to overcome. It's a long run to the front of the bus. Next time I fill her up, I'm gonna need to install a bleeder valve up near the heater core to get that air out more efficiently.

I will say that The engine runs soooo well, and the TDI starter... OMG! It's almost not fair how well this thing starts and runs. Vids to come next week Very Happy

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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/

Nepenthe88 · Posted: Tue Jul 22, 2014 10:58 am Post subject:

Ooot and abooot, eh?

Coolant gauge stands steady at 190 while driving and will climb to 205 when sitting at a light for a while. Runs REALLY well!! Very Happy

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

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a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/

GeorgeL · Samba Member Joined: January 16, 2006 Posts: 7346

tristessa · Posted: Tue Jul 22, 2014 1:56 pm Post subject:

Nepenthe88 · Posted: Tue Jul 22, 2014 5:31 pm Post subject:

Nepenthe88 · Posted: Tue Jul 22, 2014 5:46 pm Post subject:

Anyway.. it was a good FUN day today!!! I put right around 100miles on the Bus with almost 0 issues Very Happy

It didn't start off so good. I made it all of 1/4 mile down the road from the house and ran out of gas..... silliness!! I walked back and forth, filled her up with a gas can and headed straight to the watering hole to top off the tank. Then I ran some errands, and since things were doing well... I started going north with no real destination in mind. I went as far as I could. Then I got stopped... by Lake Ontario Cool

I drove along the lake for a bit and then ran into this old lighthouse. I've been in and out of B-lo for years and I didn't know this existed! Yay BUS!!

I then turned south and found a graveyard from the 1880's. There's a similar bone-yard in Syracuse (built by Olmstead if I'm not mistaken) that I used to really enjoy riding my bike through. This was like a mini version of that one.

There's even a creepy old house and soldier graves from the civil war:

A little farther and I crossed the Erie Canal on a sweet one lane bridge

And stumbled onto a railroad museum with a gorgeous locomotive. Go New York!!! Whoooo-Wooooo!!!

The only issues I had to deal with the brakes (the flexy lines need replaced as the bus turns left a little when you really jam on the stop button) and a horrible intermittent gas smell. Bleh Confused

I ran my finger across every fuel connection I could touch and they're all dry. This might take a bit of sherlock holmes-ing to find... and might require an access hatch to the treasure chest, cause ain't no way the engine's coming out again to get to the gas tank..........
_________________
a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/

Nepenthe88 · Posted: Tue Jul 22, 2014 6:06 pm Post subject:

Oh!
and I got stopped by a cop today too Confused

He strolls up and tells me his Sargeant took a pic of my bus as I was driving thru this bumblefuk little town, texted it to him and mentioned which way I was going... He tells me this and then pulls out his phone (holstered right next to his gun) and shows me a pic of HIS bus. Haha!
_________________
a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/

GeorgeL · Samba Member Joined: January 16, 2006 Posts: 7346

No. The top of the heater core is about 2" below the level of the front seat slider rails, and the radiator fill cap is flush with the bottom side of the engine compartment (I cut a hole in the body and fabricated a removable panel with gaskets to keep the crappy air out). Soooo.. it SHOULD bleed by gravity alone. And it does... it just takes a long time.

[/quote]

With that setup the hoses are below the level of the heater core so it will always trap an air bubble. The pump will move water toward the core, but as soon as the air finds the pump it loses its prime so without bleeding from the top of the heater core it takes several start/stop cycles to get rid of the air bubble.

Another solution I have seen is to run a tiny 1/8" vent line from the top of the heater core to the high point of the system that does not go down under the floor like the inlet and outlet lines. You'd have to route it either along the sidewall or up the pillars and then along the headliner. The trapped air would then have a path to the high point of the system and the heater core would fill by gravity.

I saw this done on a beetle to vent a front-mount radiator. The vent line went up and over the headliner on the right side of the car.

The advantage to this approach is that the system will stay bled even if there is an air leak into the system.

Nepenthe88 · Posted: Wed Jul 23, 2014 12:40 pm Post subject:

Petervw · Posted: Sat Jul 26, 2014 10:10 am Post subject:

Stuartzickefoose · Posted: Thu Jul 31, 2014 8:53 pm Post subject:

ill be hunting down parts in the next 3 months or so to convert the 72....im sick and tired of dads bus being unreliable!

ill have something to keep up in at least. Razz

_________________
Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

Nepenthe88 · Posted: Fri Aug 01, 2014 1:46 pm Post subject:

New gauge mock up!!! I desperately wanted a trip Odo, so I went from This:

to THIS:

It's a bastardization of some old Mercedes gauges and gauge housing + the VW fuel gauge and the frame of the gauge housing... Yes, I cut both up. The Speedometer is VDO, and uses the same speedometer cable connection as the bus. That and both vehicles ran the same 14" rims and tires, so it should be calibrated the same:

Here's the back of the Benz gauge cluster Pre- messing with it.

_________________
a Black & Blue Su-BUS-aroo

Follow my adventures in the GoWAND'RLoST bus on Instagram:
https://www.instagram.com/gowandrlost/

Stuartzickefoose · Posted: Fri Aug 01, 2014 7:46 pm Post subject:

not half shabby for a custom setup! Razz

_________________
Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

GeorgeL · Samba Member Joined: January 16, 2006 Posts: 7346

Nice! I thought that Mercedes drove their speedos from the transmission. Is it still 1:1 like the wheel-driven VW? You might need a ratio adapter.


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