Finish project started on 87 Westfalia: Bostig is going in

[JudoJeff]

I picked up a very nice 87 Westfalia today, that the PO had worked on for about two years. I'll post all the work he did, but it's a very nice unit.
The WBX engine runs, but old gas was used so that's the problem. Owner added new large brakes, but they are not connected yet.

I'm going to take out the WBX and the brand new stainless Go Westy muffler and put in a Bostig conversion to a Ford Zetec. Most of the unit has things installed but not bleed or connected. Zero miles, it was never registered.
He even delivered it to my house, and accidentally punctured one of the new tires. Darn, and he's so nice, he's replacing it.

Here's the photos you're waiting to see.

From the PO's ad:

“We've repainted the poptop and luggage carrier and installed all new seals on both. We replaced the skylight, put in new seals and new stainless hardware, and installed a new 3 window GOWESTY acrylic tent with side mosquito netted windows. We also put on new Westfalia labels.

Rear Window Seal $99.95
Rear window glass $107
Vent glass $67.99
Poptop paint $513.04
Acrylic Poptop Tent $499.95
Poptop and Luggage rack seal $89.95
Skylight seals and stainless hardware $ 61.93
LP Gas tank and regulator $379.95

We installed the new stainless exhaust, but the bolts need retightened after heating up, and the downpipe needs installed.

GoWesty Street suspension bundle
16" Alloy Wheels
Michelin Defender Tire package (in the photos you can see the paper is still on the tread)
Bilstein Shocks
Zero Lift Front Springs
Zero lift Rear Springs $1899.95
Stainless Steel Exhaust kit $699.95
Fuel Pump $31
Interstate Battery $111.38
Alternator Wire harness $39.95
V-belt bundle (all belts) $21.95
Rear Brake Drum Overhaul kit $249.95
Brake Master Cylinder $114.95
GoWesty Bigger Front Brakes $749.95
Stainless Brake Host $55.90
Rear Brake Line $25.00
Rear wheel bearing kit $112.95
All new water hoses $318.00
All new fuel and injector hoses $124
Haynes service manual $32.75
Water Hose connector $53.22
Bosch plugs $7.80
Rotor and Distributer Cap $20.13
Ground Strap $17.98
Brake Drum Hardware $17.76
Axle Nut $20.58
Firewall gas line adapter $39.00”

Besides all the manhours, he spent around $8,900!

I now have a pair of twins, double the trouble! Here's my '89:

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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)

[raoul mitgong]

The first step is admitting you have a problem.
-d
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84 Westy with a 2.1 (Groover)
86 Tintop Syncro (Crow)
86 Tintop Syncro to Westy project (Tom Servo)
91 Westy (Only the top 12 inches of this van (a burn victim))

[JudoJeff]

I've been tearing into the '87, it's in much better condition than I ever expected. (except for the mouse poop...) PO did yeoman job of cleaning and installing upgrades, now I'll finish the project. There's no rust, the Westy was undercoated at purchase. (have original purchase invoice!) The only places I've found some rust is under the sink cabinet, and the rear hatch. (Someone had broken out the rear window.) Nothing that I'd cry over.

I'm going to drop the WBX and transmission soon. The tranny is going out to AA Transaxle for a rebuild, the WBX to someone who can use it. Lots of extras with the engine, I can't use the parts, so may as well pass them along. PO installed a new GoWesty Exhaust System, but never tightened the bolts. Have to sell that off, no use on a Ford engine.

I found a Bostig kit out West, it'll be here sooner than I expected, great guy I'm getting it from. That way I'll have everything ready to install when the tranny comes back East.

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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)

[JudoJeff]

Engine and exhaust system just sold, yeah!
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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)

[JudoJeff]

Took things apart and have to say there's almost no rust. Wish my '89 was this solid! Found some under the sink, and the worse is the rear hatch. Someone had smashed out the window, and the corner has some rust.

No big deal to me, I'm happy there's so little. Shows the value of rust proofing at purchase time! The PO replaced the window and painted it beautifully.

I've dropped the engine out, it's going to a lucky buyer in VA soon. The transmission is going to AA Transaxle, as soon as I find a big box.

I bought a used Zetec engine today with 37k on it, cleanest one I've ever seen! Will post photos later on. All the desirable accessories are still on it, and nothing is cracked or broken.

The Bostig conversion kit is on its' way from Montana.
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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)

[JudoJeff]

Found a 2003 Zetec with 37k on it, excellent condition, with almost everything on it. Very clean, inside and out.

I pulled the cover to see if the cams were alright and everything is OK.

Bostig kit should be here within 10 days, then the fun will start.
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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)

[JudoJeff]

Working on connecting up the big brake package the PO bought, installed for the new 16' wheels, but never finished installing. I have all the parts,and it's fun to work on brake systems where everything is NEW!

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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)

[JudoJeff]

Original owner paid $200 for rust proofing and this shows the money was well spent, no rust! My 1989 didn't look this nice, dang!

The top is done, the undersides are done, the insides look great, now to get the Zetec engine installed. Will have to wait until the tranny comes back from AATransaxle.

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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)

[dobryan]

Wow that looks great! Enjoy. 😀
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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]

Here's somethings I did on the project: Door wiring and noticed a flap. This is the wiring before repairs, don't use wire nuts on a vehicle, they fall off.

The flap is normally missing, first one I've ever seen on a vehicle. Protects the propane tank from road debris, I guess. The PO installed a brand new LP tank, it's actually not connected yet.

The Bostig kit is due to arrive on Tuesday. Transmission was sent out for rebuild.
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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)

[JudoJeff]

Well, the engine bay is all prepped, have other things to do under there, but have plenty of time due to the long wait on the transaxle rebuild.
Note that I cut out a section of the firewall to the right. This lets you replace the starter easily from above.

The Ford Focus Zetec engine has all of the Bostig goodies on it, going to do mundane things like check the cam timing and FI's. The High Capacity Oil Pan (HCOP) keeps the oil cooler because of the increase in the amount of oil.

All new Sach's clutch, too!

Note this engine has the billet thermostat housing, a $400upgrade I'd never have bought!

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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)

[HENDO]

Nice!

I am seriously contemplating this conversion soon....
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84 Westy AKA "Sludge"

[JudoJeff]

Here's a shot of the inside, the drawer is missing and long gone. I can't find a drawer for sale anywhere, and they are rather small and useless to begin with.

If you were buying this rig, what would you like:
A drawer I made that matches the color, otherwise looks like nothing VW ever made?

OR a cover for the hole, more room under the sink?

I'm thinking of cutting out the shape, and covering it with matching formica, which I have.
Your thoughts?

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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)

[kourt]

A couple of ideas for the drawer opening:

-make a new drawer
-make a hinged door (hinge at the bottom) that is lightly spring loaded, with a magnetic utensil holder on the back (for knives, or other metal utensils)
-make a hinged door (hinge at the bottom) for a trash chute
-mage a hinged door for an aux fuse panel behind the door
-propex mounting area
-inverter mounting area
-aquarium! just kidding.
-paper towel dispenser (but the front table leg does it better)

It's a tough location, best suited for a drawer because it's too low to build a cutting board (who wants to stoop and cut onions?) and the space is awkward because of the sink drain.

kourt

[Bassyaks]

Jeff, if you don't have the drawer, where are you going to put the stuff you had in the drawer, Westys are very tight with very little extra space when your actually camping in one, your constantly moving this around to make more room. I'm sure someone could get the measurements if you wanted to have one made. I have a Full Westy and at times wish my Syncro Weekender had the kitchen , but even in the Weekender there's no room.

[JudoJeff]

I'll make a new drawer, I just hope no one ever sees it....

The zetec is all prepped, have to shove that to one side and drag out the table saw.
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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)

[JudoJeff]

Ripped out all of the fuel lines and installed new FI high pressure ones and a new fuel filter. PO told me he'd replaced them, turned out he'd added new ones on the engine, left the old VW lines in. I replaced the fuel filter, which was new, because the PO had put the 10 year old gas through it, and I didn't want any future issues from that crud. The fuel pump is new, and I drained all the gas, so should be good to go.

Next I'm doing the slave clutch and line, works but is too rusty and I doubt I'll be able to open the bleeder screw. Much easier to do while the engine bay is empty.
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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)

[Destructo]

[JudoJeff]

Put the Bostig ECU and wiring in under the rear seat. You drill a 2 inch hole for access into the engine bay. There's an OBD II extension with this kit, so I ran that and the MIL and oil warning light wires. With the OBD, you can use an UltraGauge II, giving you instant readouts on what's happening in the engine.

Here's the rear seat:

MIL and oil warning lights:

OBD II under dash:

Then I removed the seats and cleaned and greased the rotating undersides.

Before:

After:

And seats back in.

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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)

[JudoJeff]

Destructo gave me a brown replacement drawer, here it is after I painted it.
Doesn't quite match, but better than I would have built by hand.

Someone else offered a gray drawer, if that is found, it'll be a better color match.

Almost ready to bleed the brakes, I keep finding one more line to replace. (I'm much too fussy...) Project will have to sit and wait then until Matt at AA Transaxle sends back my baby.
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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)