Bostig Conversion Costs & Other Upgrades I made

JudoJeff

My Project Costs:

Here is a breakdown of my costs to install the Bostig conversion and upgrade my 1989 Westfalia with manual transmission.

The project had four phases:
1. Zetec
2. Bostig conversion
3. VW upgrades
Power steering hoses
Cooling system
Heating system
Fueling system
New Clutch
4. Air conditioning System

The zetec and Bostig are costed out separately, then combined total cost is listed.

Tools were purchased, but unless they were specific to that phase, were charged off under “tools”.

I had to repair my brake system, which was not planned.

Look at the subject line to see what costs I'm talking about.
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:43 am Post subject: Zetec Engine

Zetec

These are readily available in local junkyards, with as few as 4k on them. The engine may be missing key components, like a bracket for the A/C.

Breakdown of costs:
Zetec $532
Ignition wires 22
Valve cam cover (cracked) 45
Dipstick (missing) 15
Timing belt cover (cracked) 45
ECU 60
Alternator New 125
Spark plugs 30
Manifold nuts/gasket, etc 40
Timing tool 22
Power steering pump 52
Air box/MAF 60
Tensioner pulley (cracked) 10
Misc nuts/bolts 14
Oil filters 12
RTV 11
Ford motor mounts 204
Serpentine belts (2) 25
Coil, new 7
Haynes Focus manual 17
________
Total cost: $1348.
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:44 am Post subject: Bostig Conversion

Bostig Conversion:

Included High Capacity Oil Pan, Tachometer signal converter, OBDII extension, and MC Heat shield. I recommend you get these, they vastly improve things for you. Some of these parts could be under zetec, but it was a mix, so they got put here.

Bostig Conversion Kit $6,323
Rock Auto Parts 259
Fuel Pressure Regulator 49
Loctite 6
Coolant Temp sensor #2 15
Air filter stuff 61
_________
$6,713

Combining Zetec and Bostig costs, your total is: $1348 + $6713 = $8,061
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:45 am Post subject: VW Upgrades and Repairs:

VW Upgrades and Repairs:

Power steering hoses $290
Cooling system
radiator 150
Stainless cooling pipes 294
Radiator hoses 50
Fluids 75
Heating system
Hoses 53

Fueling system 90
New Clutch (Sach’s) 138
Slave/Master cylinders/line 160
CV Joint kits 40
Brake System
Rear 335
Front 154
SS brake hose kit 103
Tools 120
________
TOTAL: $2,052
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:45 am Post subject: Air Conditioning

Air Conditioning:

Now, I thought at first I could get by just cleaning the system and recharging refrigerant. Upon inspection of the system, it was apparent that was a pipe dream. So I went with the Eaton EZ- Clip system, and bought as much as I could on Ebay for less money. (More info on the Bostig site.)
It’s easy to do, and you save yourself a lot of moola.

Compressor $125
WPT plug 3
Manifold Gauges 37
TX valve and R/D 50
FD1603 block 43
Insulation 15
Condenser, parallel 102
EZ Clip system 79
GH134 hose #6/8/10 133
Fittings 154
Trinary switch 26
Ester oil 13
Air brake line alcohol 12
RedTek 41
Vacuum pump (cheapo) 18
________
TOTAL $851
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:46 am Post subject: Auxiliary battery

Auxiliary battery

Battery $110
Yandina 160 $107
Fuse Panel $20
Wire, fuses, etc $10
Total: $247
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:46 am Post subject: Tools

TOOLS:

I had a lot of tools, but bought more to make this easy on myself.
I won’t mention what I spent......
_________________
________________________________________
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)

JudoJeff · Posted: Mon Aug 18, 2014 9:47 am Post subject: Final Results

End result: I now have a Westy camper I can take anywhere, and not worry about breakdowns and finding parts. My system uses readily available anywhere parts, and I know how to repair it. The zetec is a much simpler design, and provides much more zip. I cruise effortlessly at 70 mph, and hills are not a problem. The air conditioning is too cold, and I keep it on fan setting of 2, cooling less than midway.

This breathed new life into my old VW, and I could not be happier!

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

_________________
________________________________________
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)

Rodknock · Posted: Mon Aug 18, 2014 2:51 pm Post subject:

Good for you, nice rig. Now about that sound-proofing project....

scottychop · Posted: Mon Aug 18, 2014 9:35 pm Post subject:

Congrats man!

dobryan · Posted: Tue Aug 19, 2014 5:26 am Post subject:

Thanks for documenting costs. I'm afraid to do that..... I really don't want to know.... ignorance is bliss..... Laughing

_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

JudoJeff · Posted: Mon Sep 15, 2014 5:25 am Post subject: Update: Am I still happy?

Well, I've driven around 5,000 miles with the Bostig; long cross country, short camping trips, around town. Everything performs as promised, I've forgotten the engine is back there. Passengers are shocked by the pickup and response.

I allowed a person who's thinking of doing the Bostig conversion to test drive it. His response: It's like driving a new car! And he was impressed by the air conditioning!

I've gone to several Connecticut VW bugfest events, not expecting to win anything, just to show what's possible. Most people have no idea you can put a Ford engine into a vanagon.

Anyone who's intimidated by the thought of doing this conversion should take comfort from knowing a dumb-ass like me did it. Bostig will NOT let you fail! You're joining a group of very dissimilar folks that understand their vehicle and can repair most anything. You'll look back and wonder why you took so long to decide.
_________________
________________________________________
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)

denwood · Posted: Mon Sep 15, 2014 6:19 am Post subject:

Excellent thread. I refrain from keeping track of parts costs, due to risk of depression. That said, you have $11K ish in + van purchase..and no labour added in. Not hard to get to $35K if using typical labour rates!

Having had the van for some years now, I tend to just set aside $500 or so each year for system replacement and pick off a job where I know service is required. As these vans exceed 25 yrs old, this habit works well to keep the van driving as good or better than new.
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Cheers,
Dennis Wood
The Grape

djkeev · Posted: Mon Sep 15, 2014 6:46 am Post subject:

Thanks for being so honest about the finances of your Van.

Many lesser folk tend to shy from giving such information lest we be ridiculed!

I know that I lean in that direction holding numbers close to my chest.......... Tough Playground at times here! I play here often, but I am very wary of Bullies attacking me..............

My Van will be up around $8000...... Ok, maybe $9000 ....... by the time it rolls but I'll be running a top end refreshed engine (w/new 1.9 rods)...... Including the initial purchase price.

No new paint,
No real upgrades,
just a put it back as close as possible to new regimen.

Labor hours however will be HUGE!!!!!

IF I were to ever consider an engine upgrade, from everything I've read to date....... I would for sure slip in a Zetec. It just seems like the best all around compromise for me. It seems I read too many horror stories of driveline failure with bigger or more powerful power plants.

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

JudoJeff · Posted: Mon Sep 15, 2014 6:48 am Post subject:

Hi Dennis,

My costs aren't in the 35k group, closer to 20k. If I was a dentist, or medical doctor, maybe my labor hourly value would add 15k, and it would be nice if I was worth that. Let's just say no one would ever hire me to fix their car!
(But all the neighbors have me work on their boat engines....)

If I paid for an engine course in school, I doubt I'd have learned as much.

$500 year for repairs is a nice idea, but even on my excellent condition California westy, I'd have shot that wad every January as the new year began. I did the other systems because I don't want to break down on the side of the road on a trip.
cheers!
_________________
________________________________________
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)

denwood · Posted: Mon Sep 15, 2014 11:25 am Post subject:

Jeff, I've always joked with the folks stopping me that to own a Westfalia, you need to be a doctor, or a mechanic Smile

I figured you'd be at around 20K all in. I'm exactly the same with respect to ownership/attitude as the van is more of a learning tool really than anything else. With a potential buyer as of the weekend, I'm really contemplating my "garage life" without it. Been looking for a work truck/daily driver so maybe a Syncro Tristar with TDI conversion next. Hmm.

In the 15 years of ownership some of the extended learning driven by van ownership:

1. Bought a MIG welder and learned how to use it.
2. Learned a ton about air/fuel performance tuning.
3. Welded my first mandrel bent performance exhaust.
4. Added another few paint jobs and new tools to the list.
5. Learned AC basics, added the tools, and got a nice working AC system.
6. Currently on a corrosion management mission: http://www.thesamba.com/vw/forum/viewtopic.php?t=606491

Not sure how I'll bring up the actual sale with my kids..both girls cried mournfully when I told them I was selling the van. Hard to explain to a child that the van is just a "thing". After reading "Zen and the Art of Motorcycle Maintenance" last year, I realize it's not just a thing, but rather a bit of journey unto itself Smile

(sniffles into Kleenex..)
_________________
Cheers,
Dennis Wood
The Grape

TequilaSunSet · Posted: Mon Sep 15, 2014 12:21 pm Post subject:

djkeev · Posted: Mon Sep 15, 2014 2:02 pm Post subject:

insyncro · Posted: Tue Sep 16, 2014 4:58 am Post subject:

$600 worth of add ons are included in the next install group from Bostig.
Most importantly, the custom oil pan Very Happy

Sale ends in two weeks.

JudoJeff · Posted: Wed Sep 17, 2014 5:37 am Post subject:

denwood,
You're getting solid advice not to sell. I loved your reply. I wouldn't trade what I've learned how to do for anything.

insyncro,
Bostig's got a great offer on the table, I wish I could have taken them up on it in RG-1.
_________________
________________________________________
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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