TheSamba.com :: View topic - Reviving my 76 Canadian Market Automatic Westy

Fri Aug 27, 2021 3:21 pm

**Build Thread since Aug 2020**

"The Good"

PO ignored the floors and rockers but replaced most of the panels and painted it, then it sat in a garage for 10 years. Dry, but a lot of rust underneath to deal with.

Fri Aug 27, 2021 4:19 pm

grab your wallet.

Fri Aug 27, 2021 4:25 pm

"The Bad"

Surprise surprise!

Expected that it had a 2L but found out the PO had swapped in a 1.7L and although it turned over, compression was very low. Pulled the engine and refreshed the top end but found that at least one main bearing was shot when I put it back in and started it. While the engine was out, I had the gas tank cleaned and replaced all the gas line hoses and got refurbished injectors. It started and ran okay except for the bearing knock but it needed the bottom end done and couldn't be driven.

If it had been a 2L I would have pulled the trigger but as it was a 1.7L, I took a good long look at other options........

Fri Aug 27, 2021 4:58 pm

"The Ugly"

Rust, rust, and more rust!

Fri Aug 27, 2021 5:18 pm

That one doesn't have hibiscus flower stickers all over the sink cabinet does it?
Looks familiar in a bad sort of way. :?

Fri Aug 27, 2021 5:19 pm

:shock:

Fri Aug 27, 2021 5:26 pm

wow, what a fucking mess.

it can all be fixed but hopefully you didn't pay more than a couple grand for this gem. i would 100% question everything the PO did on this after seeing the photos

Fri Aug 27, 2021 9:22 pm

busdaddy wrote: That one doesn't have hibiscus flower stickers all over the sink cabinet does it?
Looks familiar in a bad sort of way. :?

No, it didn't have any cabinets or front seats. Skills, got it fairly cheap so no worries.

Fri Aug 27, 2021 9:25 pm

"Got the Grinder and Sawsall out"

Sat Aug 28, 2021 8:11 am

What's going on with that LF wheel?, is the beam disintegrating as well?

Sat Aug 28, 2021 11:27 am

^^^

yea, check the beam carefully

looks like you're jumping in. the rocker is a 3 piece deal... a mid, inner and outer.

many places don't list the mid rocker but they are available

Sun Aug 29, 2021 8:25 pm

Thanks for the comments on the front beam. I had the tire leaning against the hub, not bolted on.

More cutting and cleaning. The sliding door bottom rail was rusted through in a few spots and I replaced all 4 jack points and a few floor crossmember ends.

Sun Aug 29, 2021 9:02 pm

Moving forward.

Sun Aug 29, 2021 9:09 pm

I pulled the trigger! :D

Tue Aug 31, 2021 8:48 am

Harness pull

Did the harness myself as I extended the wires to the front of the bus to use the Subaru speedo unit, heater/A/C control unit, cruise control, radio & speakers, and included power wired for AUX battery power up front as well as added a wireless security/anti-theft system to disconnect the starter and fuel pump. Added a start relay and extra wires from the ECU to the Code Cheat board.

Wed Sep 01, 2021 8:24 am

Engine work - Subaru 2.5L SOHC from a 2000 Legacy with 140,000 kms

Swap Kit: KEP Adapter and drive plate, KEP exhaust header, Small Car shortened oil pan, Small Car Code cheat board, throttle cable & kickdown mount for Vanagon Auto transaxle, Busaru engine support crossmember, throttle reverser, & speed sensor. Subaru OEM gaskets, seals, and timing kit. Vanagon Catalytic Converter & a Bugpack muffler.

Had the heads ground flat, did the valves myself with grinding compound, new head gaskets, new head bolts, intake & exhaust valve seals, cam seals, rocker cover gaskets & seals, new rear main seal, reseal of rear plate, new intake gaskets, and new timing belt kit with new waterpump, tensioner & pulleys, etc.

Wed Sep 01, 2021 8:32 am

Transaxle swap from an 003 to a 010 from a 1986 Vanagon for the external oil cooler. Had the 010 rebuilt before install. Had to modify the front mount and move the gear changer to the opposite side and make up some adapters to make it work.

003

010

Wed Sep 01, 2021 9:10 am

Belly Rad

Used the Subaru rad and fans out of my donor as well as the overflow tank. Used heavy duty marine exhaust hose rated for the temp, materials, and operating environment. Added 4 connecters: 2 at high points in the coolant lines for bleeding air that lead up to a filling point (with shut off valves) just under the rear access hatch and the other 2 at the inlet and outlet of the rad to install temp sensors, wired to aftermarket gauges to monitor temps before and after the rad. Added a temp/thermo (180F) switch in the outlet connector of the rad to control the cooling fans and ran the ECU fan control wires to the Small Car Code cheat board. Angled the rad and covered with a protective screen instead of making an air scoop. May fab a scoop over the winter. All coolant hose that touches metal (or anything else) is protected by 2" PVC pipe to protect from abrasion or damage.

...and yes, those are aluminum hockey stick shafts that the rad is mounted to as it is a Canadian Market bus after all.... :D

Wed Sep 01, 2021 10:33 am

Heater - A/C unit

Piped the Subaru heater - A/C unit through the floor and ran a 3" insulated duct up to the front connecting to the original defrost heater deflect tree/unit.

*Added speakers from the donor and the 1.5" outlets under the speakers are heater-A/C air outlets.*

*Subaru Heater Control Unit that is tied into the defrost tree's mechanical lever and the rear defrost button is connected to the Bus rear window defrost too. Used one of the heater unit's vent actuators to control heat or A/C damper on the heater unit under the back seat using the unit's air recirc button between rear defrost and A/C button. Only issue is it's either full heater or full A/C but will have to see how this works out and modify if necessary.*

Wed Sep 01, 2021 10:34 am

Fantastic progress so far!