(My) Perfect '84 Wolfsburg Build

[10degnorth]

[10degnorth]

Got to some suspension work last weekend.

New:
Upper ball joints
Front Bushings all around
Outer tie-rods
T3 Technique extended/adjustable Spax shocks
Shwenk "Westy" Springs

All things went well until I got things torn down to the lower balls. I stared at them, stared at my ball joint C-Clamp, back at the lower ball joints. Then I folded arms and went "Hmmmpf". Then I proceeded to put everything back together with the original lower ball joints, that's a problem for future me.

Seriously thought, if you have any suggestions on getting those things out I would love some input. When I get some more time I think I'll pull out the heat and the airhammer. I have seen it suggested in another thread that I should just smack them real hard with a sledge, but that irks me the wrong way.

**Forgot to get pictures of the nice shiny new stuff, I'll add some later**

On my last van I had a lift and as recommended used the GoWesty upper ball joint spacers, the issue that I faced with that is that due to my ET30 wheels the lip of the upper A-arm rubbed a groove in my front tires. To pro-actively alleviate that issue, I took it upon myself to clearance the upper A-arms by cutting 2 slots and adding a relief cut then bending the furthest edge about 1/2" inwards then welding it all up again.

I am also making progress on the hightop, but I will keep that in my other thread.

Also added a gear reduction starter to fix my inconsistent start issue. The 40 year old starter doesn't like the 20% higher compression EJ22.

Cheers!

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[Vangabonders]

[DuncanS]

Is the top on backwards in this photo. I know you mentioned the "tongues", but judging by the slope of the windshield, it seems like it would be happier the other way around. At least put it on the other way and post a pic. With 5200, you don't need tongues to hold it on.

Duncan

[?Waldo?]

I wouldn't take the time to replace the suspension bushings (especially upper control arm bushings) and use anything other than Powerflex.

[10degnorth]

[10degnorth]

[10degnorth]

[Wildthings]

[RoryGirl]

Look at the distance to the first "rib"...he's got it on the right way
_________________
1991 Double door pop top conversion

[DuncanS]

No matter which way you put it on, make sure to reinforce the less sloped end for the outboard motor when you take it off and use it for a boat. The ribs are there to introduce air so the suction of the water won't keep it from planing at full power.

Duncan.

[10degnorth]

I’m hearing a new clunk.

When I let off the gas and coast then pick up on the gas again quickly it goes dunk dunk. Sounds like something is twisting and hitting something from the torque of quick-ish acceleration.

My first thought was something hitting the deck lid, pulled that and drove around, still got the sound. Found my air box was loose, tightened it down, still get the sound.

Now I’m thinking maybe my trans mount is dead or going out. How does it look? Im not sure what the threshold for a bad mount is on these.

If not the mount, maybe a CV noise? Mine are definitely going out and I have some new 944’s to put on but haven’t yet.

Any suggestions? Thanks.
_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[mikemtnbike]

Loose rear shock can kind of sound/behave like that.
_________________
1991 Vanagon GL 2.1 AT Westfauxlia. "Frankie" Totaled https://www.thesamba.com/vw/forum/viewtopic.php?t=764510&highlight=carnage
1995 Eurovan Camper "Marzivan"
2020 GTI SE manual

[DuncanS]

I don't know what his should look like, but there appear to be cracks all over the place and tears near the weld. Looks scary to me. I'm going to crawl out and look at mine in the morning.

Duncan

[10degnorth]

[10degnorth]

The Powerflex bushing fixed the acceleration clunk.

Pulled out the trans mount.

Removed the OG rubber bushing and the metal sleeve from the mount.

Pressed the new Powerflex bushing in with the stainless sleeve and installed.

Power delivery feel much smoother now.

I have been on a crusade against clunk and noises lately. I went ahead and installed the 944 CV joints that I have had sitting around since I got the van. That fixed the CV clunk that's been bugging me for the last 2 weeks since I tore a boot.

Next, I need to get an exhaust leak welded up, replace my whining fuel pump, and clean up the squeaky breaks.

My exhaust manifold cracked at the head flange. This manifold was free out of a van shop's scrap pile so I don't feel too bad about it cracking. I have a couple friends who TIG weld to get that stainless fixed up.

May have found another Westy top for a good price that might end up on my van, I am torn between the Westy top and the Reimo small top from Bjorn's up in washington. Its about a $1500 difference to get the Reimo. Which may be the deciding factor.

I threw a luggage rack on the van just to see how it'd look.

Also took the van on its maiden journey up to Mt. bachelor. She did great, didn't drop below 50 the whole way. All the tech-bro ski bums with their sprinters vans came to see what was making all the noise.

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[10degnorth]

Lately, when people ask me what my next van project is my only response has been "Use it". And use it I have! Things are thawing out here in Bend and the camping season has begun. I think I am nearing 20 days in the woods this year.

This week I went out on a mission to find wet stuff and get the van dirty so i thought I'd share some of my pictures from the adventure!

Here's a pic of our little offroad club.

Scouting the mud hole (I am the one closer to the van).

Sending it.

Post-run glamour shot. Check out the free paint on the front wheel .

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[10degnorth]

In my pursuit of a slightly ridiculous van I’ve been thinking about upping my tire size to 235/75/r15. I know that 215/75/r15 is the common sense size limit but they just still look a lil dinky to me. I’m only seen two a couple vans try for these big tires. One being the Descend van. Today while walking around a neighborhood I found a blue Syncro that was sporting this large size as well and with less clearance issues than I though it would have.

I was surprised by the clearance that remained between the rear trailing arm and the tire.

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[10degnorth]

Descend 2023 was a blast! It was my 3rd year and I spent the weekend hanging out with the Crooked/Small Car crew.

I got up the guts to jump the van (probably a dumb idea but we made it happen). The only carnage I’ve found so far is my oil pressure sender delaminated (probably unrelated) and I snapped the drop link of my sway bar. For being my only car I’m awfully tough on this thing probably time for a rest and a very detailed inspection.

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7

[10degnorth]

I got access to a 3D scanner at work a couple weeks ago and scanned the rear fender of the van.

With this I was able to model up a rear spat similar to the factory Syncro ones but a little wider and in a shape I like a bit more (plus at ~$100 euros per spat I’m saving some money over the repops). Put the 3D printer to work and busted out a pair of them in ABS plastic and then spent the afternoon prepping, sanding, and bed lining them. The attachment method could be improved in the next version, but for now it will be VHB tape.

_________________
1984 Wolfsburg Vanagon (Current Project): https://www.thesamba.com/vw/forum/viewtopic.php?t=773912&highlight=

1988 Microsquirted, Wolfsburg Vanagon (Sold): https://www.thesamba.com/vw/forum/viewtopic.php?t=708000&highlight=

Microsquirt Conversion Guide (Work now Discontinued): https://docs.google.com/document/d/1laXykNPbRYS8MT...2imqd2pnx7