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Led Instrument Panel Upgrade
Posted: Tue Sep 19, 2017 6:10 pm
Size: 800x599   Views: 19
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Led Instrument Panel Upgrade
telford dorr
Here's some pics of the tach LED bulbs (official VDO - ouch!) and the dash lit up


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Led Instrument Panel Upgrade
Posted: Tue Sep 19, 2017 6:10 pm
Size: 800x599   Views: 14
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Led Instrument Panel Upgrade
telford dorr
Here's some pics of the tach LED bulbs (official VDO - ouch!) and the dash lit up


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LED Instrument Panel Upgrade
Posted: Sat Aug 19, 2017 6:46 pm
Size: 800x599   Views: 7
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LED Instrument Panel Upgrade
telford dorr
These pics show a flexible LED strip installed in a Bay bus instrument housing. The LEDs used are Pilot CZ-3143W 2 per package, only 1 needed, Pep Boys). Working on a dimmer module which uses the original headlight switch as a control input.


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LED Instrument Panel Upgrade
Posted: Sat Aug 19, 2017 6:46 pm
Size: 800x599   Views: 8
Rating: Not rated
LED Instrument Panel Upgrade
telford dorr
These pics show a flexible LED strip installed in a Bay bus instrument housing. The LEDs used are Pilot CZ-3143W 2 per package, only 1 needed, Pep Boys). Working on a dimmer module which uses the original headlight switch as a control input.


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LED Instrument Panel Upgrade
Posted: Sat Aug 19, 2017 6:46 pm
Size: 800x599   Views: 6
Rating: Not rated
LED Instrument Panel Upgrade
telford dorr
These pics show a flexible LED strip installed in a Bay bus instrument housing. The LEDs used are Pilot CZ-3143W 2 per package, only 1 needed, Pep Boys). Working on a dimmer module which uses the original headlight switch as a control input.


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LED Instrument Panel Upgrade
Posted: Sat Aug 19, 2017 6:46 pm
Size: 800x599   Views: 9
Rating: Not rated
LED Instrument Panel Upgrade
telford dorr
These pics show a flexible LED strip installed in a Bay bus instrument housing. The LEDs used are Pilot CZ-3143W 2 per package, only 1 needed, Pep Boys). Working on a dimmer module which uses the original headlight switch as a control input.


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Hella 12 Volt 9 Pin Flasher Module
Posted: Sat Jul 15, 2017 1:41 pm
Size: 1600x1197   Views: 11
Rating: Not rated
Hella 12 Volt 9 Pin Flasher Module
telford dorr
This is a very well made unit (way better than most). It has a removable cover, and is easy to service. If you have one, consider it a premium quality unit.


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Hella 12 Volt 9 Pin Flasher Module
Posted: Sat Jul 15, 2017 1:41 pm
Size: 1600x1197   Views: 8
Rating: Not rated
Hella 12 Volt 9 Pin Flasher Module
telford dorr
This is a very well made unit (way better than most). It has a removable cover, and is easy to service. If you have one, consider it a premium quality unit.


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Hella 12 Volt 9 Pin Flasher Module
Posted: Sat Jul 15, 2017 1:40 pm
Size: 1600x1197   Views: 8
Rating: Not rated
Hella 12 Volt 9 Pin Flasher Module
telford dorr
This is a very well made unit (way better than most). It has a removable cover, and is easy to service. If you have one, consider it a premium quality unit.


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Hella 12 Volt 9 Pin Flasher Module
Posted: Sat Jul 15, 2017 1:40 pm
Size: 1600x1197   Views: 8
Rating: Not rated
Hella 12 Volt 9 Pin Flasher Module
telford dorr
This is a very well made unit (way better than most). It has a removable cover, and is easy to service. If you have one, consider it a premium quality unit.


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German Equiv. Crimp Terminals
Posted: Tue Jun 06, 2017 5:19 pm
Size: 1600x1197   Views: 6
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German Equiv. Crimp Terminals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 12
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Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 5
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Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 3
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 4
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 5
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 3
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Forum code:
 
Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 2
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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Forum code:
 
Ignition Switch Internals
Posted: Wed May 24, 2017 8:42 pm
Size: 1600x1197   Views: 4
Rating: Not rated
Ignition Switch Internals
telford dorr
These pics show the internals of a 1971 bus type ignition switch, describing damage caused by heat. With some careful rework, a damaged switch may be able to be repaired enough to allow the velicle to be driven to a place where more permanent repairs can be made.


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German Equiv. Crimp Terminals
Posted: Thu Mar 30, 2017 10:14 pm
Size: 1600x1197   Views: 22
Rating: Not rated
German Equiv. Crimp Terminals
telford dorr
These pics show common AMP "F" crimp terminals as used on OEM wiring harnesses in VW's. These include the current (as of 4/2017) Digikey part numbers for quantity 1 orders. See http://www.digikey.com for more info.
Note: non-piggyback terminals have the retaining tab to keep the pin in the OEM plastic housings.


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German Equiv. Crimp Terminals
Posted: Thu Mar 30, 2017 10:14 pm
Size: 1600x1197   Views: 29
Rating: Not rated
German Equiv. Crimp Terminals
telford dorr
These pics show common AMP "F" crimp terminals as used on OEM wiring harnesses in VW's. These include the current (as of 4/2017) Digikey part numbers for quantity 1 orders. See http://www.digikey.com for more info.
Note: non-piggyback terminals have the retaining tab to keep the pin in the OEM plastic housings.


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Cam Bearing Failure
Posted: Fri Jan 20, 2017 4:45 pm
Size: 800x599   Views: 18
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Cam Bearing Failure
telford dorr
This pic shows the left middle cam bearing out of a stock type 1 engine installed in a '71 bus. The curious thing is that the right half of the bearing was fine. The engine has a full-flow filter setup.


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AL82 Alternator Hack
Posted: Sun Jan 08, 2017 6:13 pm
Size: 1600x1197   Views: 24
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AL82 Alternator Hack
telford dorr
This is how you can convert an internally regulated alternator to an externally regulated one. Why do this? Well, for a start, it puts the regulator somewhere you can get at it without dropping the engine...

NOTE: NOT FOR PURISTS! Avert your eyes now...


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AL82 Alternator Hack
Posted: Sun Jan 08, 2017 6:12 pm
Size: 1600x1197   Views: 14
Rating: Not rated
AL82 Alternator Hack
telford dorr
This is how you can convert an internally regulated alternator to an externally regulated one. Why do this? Well, for a start, it puts the regulator somewhere you can get at it without dropping the engine...

NOTE: NOT FOR PURISTS! Avert your eyes now...


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AL82 Alternator Hack
Posted: Sun Jan 08, 2017 6:12 pm
Size: 1600x1197   Views: 15
Rating: Not rated
AL82 Alternator Hack
telford dorr
This is how you can convert an internally regulated alternator to an externally regulated one. Why do this? Well, for a start, it puts the regulator somewhere you can get at it without dropping the engine...

NOTE: NOT FOR PURISTS! Avert your eyes now...


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Ford Starter Relay
Posted: Thu Nov 03, 2016 11:41 am
Size: 1000x1000   Views: 20
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Ford Starter Relay
telford dorr
This is recommended as a "hot start" relay over a regular Bosch cube relay, as it can handle much more current and is designed for the purpose.

Connections:
- left lug = battery
- left screw = start signal from ignition switch
- right screw = unused
- Right lug = signal to starter solenoid
- relay mounting ears = ground


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Electronic Fuel Gauge Voltage Regulator
Posted: Thu Nov 03, 2016 11:04 am
Size: 1100x850   Views: 23
Rating: Not rated
Electronic Fuel Gauge Voltage Regulator
telford dorr
This circuit is a non-adjustable version of a previous circuit. It uses 1% metal film resistors (source: Digikey, Mouser) for accuracy and stability. It's advantage over the mechanical and zener versions of the stock regulator are (1) no stereo noise, and (2) cooler running (less heat).


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Aftermarket Fuel Gauge Voltage Regulator
Posted: Tue Nov 01, 2016 5:51 pm
Size: 1096x548   Views: 159
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Aftermarket Fuel Gauge Voltage Regulator
telford dorr
This is the schematic of the aftermarket voltage regulator being sold for use on late bay buses.


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Aftermarket Fuel Gauge Voltage Regulator Fix
Posted: Tue Nov 01, 2016 4:58 pm
Size: 1600x599   Views: 67
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Aftermarket Fuel Gauge Voltage Regulator Fix
telford dorr
This pic shows where to solder the rivet and metal parts together to eliminate flaky operation.


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Sensor data with correction resistor
Posted: Tue Oct 25, 2016 6:11 pm
Size: 750x402   Views: 15
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Sensor data with correction resistor
telford dorr
This shows a comparison of the DougB TS2 sensor with paralleled correction resistor vs a VW OEM TS2 sensor. Looks pretty close to me...


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Sensor, corrected
Posted: Tue Oct 25, 2016 6:01 pm
Size: 237x385   Views: 8
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Sensor, corrected
telford dorr
By paralleling the DougB sensor with a 33,000 ohm resistor, the value can be brought much closer to the VW OEM sensor - probably close enough, except for maybe artic conditions. Certainly much better than just shorting the sensor wire to ground...


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TS2 sensor test method
Posted: Tue Oct 25, 2016 5:31 pm
Size: 1600x1197   Views: 18
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TS2 sensor test method
telford dorr
Two ohmmeters were used (one for each sensor). The temp meter probe went into an oil-filled well between the sensors.


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DougB vs VW OEM TS2 sensor test
Posted: Tue Oct 25, 2016 5:17 pm
Size: 968x424   Views: 90
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DougB vs VW OEM TS2 sensor test
telford dorr
This shows the raw data and plot of the sensor DougB came up with compared to a NLA VW TS2 sensor. The data was gathered twice - once warming it up, then cooling it down. The important thing here is the difference between the two sensors, not the absolute temperature values.


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TS2 sensor test fixture
Posted: Sun Oct 23, 2016 1:45 pm
Size: 1600x1197   Views: 53
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TS2 sensor test fixture
telford dorr
This fixture is for plotting the resistance curve of a TS2 FI head temp sensor.


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Minimum Wiring to Run Engine
Posted: Tue Sep 06, 2016 11:55 am
Size: 1600x957   Views: 24
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Minimum Wiring to Run Engine
telford dorr
This schematic shows the absolute minimum wiring needed to run an engine. This id for a 1970 bus, but is typical. If you have FI, then it's not so easy (but still doable).


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Conversion to Euro-style Taillights
Posted: Sun Aug 28, 2016 3:40 pm
Size: 950x612   Views: 8
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Conversion to Euro-style Taillights
telford dorr
This schematic shows the wiring changes needed to convert to dual bulb red/yellow Euro-style taillights. It is shown for a '71 bus, but other models are similar.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 22
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Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 20
Rating: Not rated
Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 14
Rating: Not rated
Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 12
Rating: Not rated
Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 19
Rating: Not rated
Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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Build a fuel hose adapter
Posted: Fri Aug 12, 2016 11:39 pm
Size: 1600x1197   Views: 15
Rating: Not rated
Build a fuel hose adapter
telford dorr
Rather than force a fuel hose onto a too large fitting, or over-clamp a too large hose onto a fitting, why not make an all-metal adapter to join two different size fuel hoses together? It's not hard at all.


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9-pin flasher internal functional schematic
Posted: Sat Jul 09, 2016 10:30 pm
Size: 800x600   Views: 30
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9-pin flasher internal functional schematic
telford dorr
This schematic shows functionally how the 9-pin flasher works. The actual unit may be an optimized version of this, combining contacts to minimize costs.


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Hose clamps - bad, good
Posted: Mon Jun 20, 2016 2:52 pm
Size: 800x599   Views: 33
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Hose clamps - bad, good
telford dorr
The leftmost clamp is the normal FLAPS clamp and not what you want - damages the hose. Next clamp is much better, and available through Amazon. Next clamp is the best (note rolled edges), but hard to find. The rightmost clamp is a permanent clamp (Oetiker ear clamp) and is good for the stub hoses on fuel injectors, and other places not desiring disassembly.


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Gen/Alt Test Stand
Posted: Tue Jun 14, 2016 8:10 am
Size: 800x599   Views: 45
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Gen/Alt Test Stand
telford dorr
I cobbed this together to be able to bench-test generators, alternators, and regulators. It uses an old 1720 RPM motor (1 hp - probably overkill...), an old generator stand, a length of 2x8, and some bolts. Simple...


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Oil Drain Passages
Posted: Sat Jun 11, 2016 9:01 pm
Size: 600x800   Views: 46
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Oil Drain Passages
telford dorr
These passages drain oil from the flywheel seal and the cam bore plug areas. They can get plugged with case sealer if one is too generous with it.


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Baybus 77-78 Fuel Injection Wiring detail schematic
Posted: Wed Dec 16, 2015 12:55 pm
Size: 1325x907   Views: 19
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Baybus 77-78 Fuel Injection Wiring detail schematic
telford dorr
This schematic shows the critical aspects of the FI wiring for late bay buses.


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Headlight Relay Types
Posted: Fri Jul 31, 2015 12:06 pm
Size: 1063x800   Views: 22
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Headlight Relay Types
telford dorr
This image shows the US style headlight relay (aluminum case) and the Euro style headlight relay (black case). On the Euro relay, the fifth terminal (terminal 30) is used electrically. On the US relay, it's just a retainer. Thus, the Euro relay cannot be substituted for the US relay without adding a wire to the relay socket.
You can substitute the US relay for the Euro, butt why would you want to?


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Early bay window bus fuel sender repair
Posted: Tue Jun 09, 2015 1:09 pm
Size: 800x599   Views: 54
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Early bay window bus fuel sender repair
telford dorr
The pics show the repair sequence of early bay window bus canister fuel senders.


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Early bay window bus fuel sender repair
Posted: Tue Jun 09, 2015 1:09 pm
Size: 800x599   Views: 14
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Early bay window bus fuel sender repair
telford dorr
The pics show the repair sequence of early bay window bus canister fuel senders.


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