81 Cali air-cooled conversion to something better?

[mcamp]

Looking to upgrade engine and possibly transmission depending on upgrade. I have an 81 Cali air cooled (live in Houston) and want to add power and “reliability “ to van.

I would like a Bostig conversion vs Subaru. Seems like parts more available and I’ve heard it’s more reliable. From what I’ve read it’s more expensive too do so downside to that. Most of my trips so far have been only and hour away and In the colder temp months. Texas heat is hard on air cooled. I’m not looking for super power just something that can get me up to speed without getting out to push.

Any conversions doable in the 5k-7k range? I would have to have a shop do it.

Open to any option really. Just want a little more modern equipment where I’m not counting on 37 yr old plastic or wires. And yeah I know it’s an old car and modern equipment is a loose term.

[AZ Landshaper]

I converted an 81 to subaru 2.2 L. Its awesome but the amt of work required and the cost may not be in line w the value of the van. Now maybe you dont give a rats ass about that. I didnt.
When you do a conversion from an aircooler to a water cooler there is a lot of extra work in assembling a cooling system not to mention a new heating system for the cab and window defrost. shit the list is long. Its a labor of love.
I would never convert an aircooler again. Id find even a beat watercooled van and go that route. From low coolant alarms to an existing radiator and well engineered heat. There are too many advantages..

That out of the way....there is no greater jump in performance than an aircooled van converted to modern day horse power. And reliability is exponentially increased. Its awe inspiring but I would have to really be attached to a aircooler to make this type of effort again. Mine has been nothing but powerful and responsive and reliable since I got the suby conversion running.
hit me up if you need any help w the nuances of this project... Love to help.
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85 Weekender w/ EJ22
Previously
64, 71, 72, 73, 76, 81, 84, 85 & 87 Campmobiles and Westfalias
and a 67 bug.

[MarkWard]

If I were you, I would keep an eye for a 2.7 or 3.0 Porsche 911 engine and transmission. I drove one for a day and all I can say is wow. You keep it air cooled and it fits with minor work.
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[Vanagon Nut]

There's no doubt that the installation of a cooling system adds more work but in terms of the dash and heat box, some vans need a heat box reseal so you'd be into the dash and heat box anyways. And, by doing an air to water cooled swap, you'd have a near new cooling system in the bargain. That counts for a lot IMO. If it was me, in hindsight, I'd source a WBX heat box, rad fan/shroud, fan wiring/plugs then if need be, make the support brackets for rad. Heck if one wanted to, they could make their own lower rad grill and the OE type cardboard pieces that go around the rad. There might be an image of those in the gallery showing dimensions?

FWIW, I've been running the older smaller diameter long coolant pipes with out any obvious determent to the cooling system capability. Using new stainless 1.9 type pipes will save you some work as they fit in the OE frame holes which I assume your bus has. My '81 did.

There's plenty of other things to do like running new wires back to front, installing the oil pressure "L" board, rad fan wiring, that also take more time. Would I do that conversion again? If the bus had a great body, yes. Then again, if an air cooled with busted engine but otherwise good drivetrain etc. fell in my lap for the right price, I'd rebuild the 1.8 8v VW engine, used rad etc I have lying around and put those in. But I digress....

Neil.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

[mcamp]

Yeah I know it’s a ton of effort but I’ve done a bit to the interior and there’s very little rust on it so the body is solid and I would rather put more money into this one than risk some unknown new van. I’ve had brake system redone too. Heater doesn’t work so new system is great that it would fix heater.

The van has an air conditioner system so not sure if I’d try and fix that or just replace w new system. The coil is just behind the front grill so new radiator might have to go where spare tire is and tire on rear rack.

I’m not even sure if 5-7k is a realistic budget for Subaru or bostig.

[AZ Landshaper]

DIY subaru for 5 k is doable.
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Support Small Business.

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85 Weekender w/ EJ22
Previously
64, 71, 72, 73, 76, 81, 84, 85 & 87 Campmobiles and Westfalias
and a 67 bug.

[Zeitgeist 13]

DIY VW inline four w/factory diesel 50 degree kit is doable for $3k or $4k. No need to sell your soul. My TDI install was a little more than $3k, though it was super double extra DIY.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[mcamp]

Would not be a dyi as I don’t have the time or skills to pull that off.

[Zeitgeist 13]

Your price range basically eliminates all the major "kit" swaps, unless you find one that someone is removing and selling in favor of an upgrade.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[weswsimpson]

You can do a Subaru swap cheap by using subie exhaust manifold, radiator, etc. Search "pokevan no more" for my build notes

[mcamp]

If price range needs to go up to be realistic so be it. Just really looking for best option and money well spent or bang for buck on upgrade and reliability.

[mcamp]

The other option is to rebuild the ac motor and upgrade the hell out of everything to give it a few more HP. Still $$$ but should be less work for other systems.

[Zeitgeist 13]

That's a perfectly viable option; not cheap, but hands down the least complicated way forward.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[AZ Landshaper]

Would not be an option for me. The camper special which was the highly recommended option was more than my subaru.
I doubt theres an option for less than 6 w a water cooled engine when your paying for labor. Im not sure there is an aircooled option for less than 6 when you consider the costs of labor.

Mcamp, what would you be upgrading the hell out of to get more horses? I deff didnt find any reasonable upgrades avail when I was considering the fate of my pancake motor.

But Im not looking back now.
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Support Small Business.

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85 Weekender w/ EJ22
Previously
64, 71, 72, 73, 76, 81, 84, 85 & 87 Campmobiles and Westfalias
and a 67 bug.

[Vanagon Nut]

[mcamp]

If it’s over 6k then I just need to plan for that.

The upgrades for air cooled I’ve seen are bigger heads, different fuel injection system, new air intake, exhaust upgrade, and added oil cooler capacity. Some have regeared as well.

The air cooled Porsche engine sounds like a great idea. Most I’ve seen haven’t been able to fit without modifying the engine cover

[AZ Landshaper]

I like the TDI. Good motor there. Sounds like you need to buy some wrenches.
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Support Small Business.

-------------------------------------------------------
85 Weekender w/ EJ22
Previously
64, 71, 72, 73, 76, 81, 84, 85 & 87 Campmobiles and Westfalias
and a 67 bug.

[Vanagon Nut]

[mcamp]

Would not object to TDI swap. The GoWesty folks sound like that’s not the best conversion but I wouldn’t oppose it. Would have loved to have kept my Jetta tdi and put it in but I did the recall and took the money and ran.

Sounds like cheapest would be keep and upgrade air cooled then Subaru swap then bostig or tdi somewhere above Subaru.

Just tired of the drama of trying to start it every time and then watching temps rise on highway and people blow past me.

[zuhandenheit]