Installation notes: Bostig's new "catifold" exhaust system

[MsTaboo]

OK, Jim has stepped up and offered me a solution. I'm not really at liberty to disclose what it is (he can if he wants), it's not perfect but helps for now.
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Currently:
'90 Syncro Westy 3 knob w/Zetec

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[jfu057]

Here are my pics of the new exhaust clearance and the block from summit that fits with the 90 degree hoses.

I don't see why this is such a big issue on this thread. The new design is clearly an improvement. Everybody just calm down. figuring sh*t out is half the fun of doing something like this.

[JudoJeff]

jfu507,
4stars, nice post.

Are the aircraft clamps tight enough for fittings? Will the plastic handles melt?
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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)

[MsTaboo]

Excellent jfu057.
Looks like the EZ-Clip fittings?
Have you run the system yet?
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
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[jfu057]

[jfu057]

[jimf909]

Thanks for working through this, folks.

It looks like the elegant solution will be a similar block with fittings straight up(?). It’s a shame that Jim didn’t call out the easily anticipated fit issues with some/many/most of the existing custom a/c configurations (it seems that any engine conversion is a custom configuration) but I appreciate his follow-up.

I also appreciate all of the early-adopters who explore and share and make implementation much easier for those of us who follow. Having just completed another trouble-free multi-day trip in triple-digit temps I have to say I love my Bostig and functioning a/c. The Vanagon is so much better with both. Thanks, y’all!
_________________
- Jim

[Guybrush]

Cool, thanks for the solution. I wonder if the hoses with a current EZ-clip installation would just turn and connect properly without redoing the clips, but buying a few more in advance might be best. Looks like straight up connectors would work even better but I guess it's about how you attach the hoses to clear the serpentine belt anyway.

[bostig]

[MsTaboo]

Just a quick follow up on this. We're facing a evacuation order because of a bad fire just up the valley from us (families a little ways further up the valley have already been ordered out), so I'm rushing to get ready to scram.

Instead of waiting for the different a/c block Jim is sending me, I just capped off the a/c compressor and lines so I could finish installing the new catifold.
I did receive the alternate block from Summit, but I'm gonna be a test for Jim's block so waiting to refill the a/c.
https://www.summitracing.com/int/parts/vta-045018/overview/
These are the three available blocks for the FS10 compressor.

The install went fairly easy except I did elongate some holes in the inner shield so I could get all the fasteners through the Walker cat and into the outer shield.
One other thing to mention for people doing a replacement install, make sure you take the time to check the oil dip stick holder against the heat shields and make needed adjustments.
I forgot about it until the very end and had a bit of fussing to get the new bends with everything in place.
Here are a some extra photos.

(make any changes at your own discretion, this worked for me, YMMV)

I was able to get all the fasteners into the heat shields with a bit of fussing.
A little bit concerned that the lower brace that supports the cat will transfer heat to the block (maybe a standoff made of something heat resistant?)

You can see how much extra room the new system creates.

Took the van for a quick warmup run last night, did not notice any difference in driving but the rear compartment over the engine lid was definitely cooler.
So, once again I have to say I really like the idea that Jim went with despite the problems with a/c clearance.
I still say it would have helped to tilt the catifold upward away from the engine block, increasing clearance and airflow between the catifold and the block. IMHO
Kudos to Bostig/Jim for working to make his conversion kit better and better.

Now back to packing up the trailer and the van with our valuables. Hope we get some rain soon.
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
Help the fight against Truth Decay.
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[jimf909]

It's good to see this shaping up well after a rough start.

Here's hoping the fires slow down soon.
_________________
- Jim

[MsTaboo]

OK, I got the steel compressor block from Bostig and after some delays got out and did some test fitting.

Here's the block compared to the 45* aluminum block. Main benefit of this block is it's made of steel, so pretty much bulletproof.

And installed on the compressor. Bit of a tight fit on the suction side for the nut on the fittings.

Unfortunately the 90* fittings I have hit the main coolant hose when doing a rear hose route. It may be that 45* fittings will arch over the hose.

Ended up using the aluminum 45* compressor block.

I'm thinking of ordering a pair of 45* EZ-Clip fittings so I can use the steel block. I have doubts about the strength of the aluminum tubes on the 45* compressor block.
If you use the 45* block be very careful when tightening the fitting nuts to keep a wrench on the block side. Tube will twist very easily. Space is tight and I ended up tightening the fittings to the block first and then installing the block to the compressor.

We're still under forest fire evacuation alert here, but got a little rain last night so hopefully the worst is over and we won't have to scram.
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
Help the fight against Truth Decay.
Defend democracy, support Ukraine.

[shizzon]

[MsTaboo]

[jimf909]

[MsTaboo]

[Bcassin]

Ms Taboo,

Could you show a pic of how you have the ac hoses routed through the rear of your engine bay?

[MsTaboo]

[kourt]

I'm starting my RG9 exhaust upgrade this weekend.

The old RG1 cat finally popped its oxygen sensor port, so it was time to make the change.

I also needed to rebuild the hoses for the AC system near the engine, so I get a 2-for-1 on this job.

Here's some photos of the existing RG1 system, and some rehabilitation of the AC lines. I am using the 45 degree FS10 block and new 90 degree hose ends. I'll update this thread later when I've got the rest put together.

kourt

[jimf909]