1991 Multivan TDI build

[coqcitywesty]

^^^^ Echo the comments above on the relay - never knew this existed, so it's now on the shopping list.

I also admire your restraint with the flying tent issue and damage to the new paint - I am not sure that I would have been able to manage my emotions quite so eloquently/calmly as you have described given the wait and anticipation. My ES goes in next spring for its body restoration which will inevitably bring a new level of paranoia as to where I park it. Hopefully the Westy will go in the following year for the same treatment....

Love the Orly Blue and love the end result - congrats!
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1991 Westfalia EJ251, 1972 Volvo 1800 ES

[DuncanS]

Nick--One of the great things about your 45 pages is it is a wonderful combo blog and mechanical experience column. I won't say posts as it has gone way beyond that and rhere are a number of us who appreciate what you have done and the experiences you have shared.

So two reasons for this currennt comment. 1. We need an index that somehow will guide us towards the posts that could help the rest of us ignorant dudes figure out how to profit from your experience. Wandering through 45 pages hoping to find the exact spot is a bit tedious to say the least. And number the next--2--I believe--is what are you up to? We miss your adventures, such as the proposed drive up Mt. Washington--and hope your have been able to enjoy your shiny new Pippen. In this covid time, getting out of town, or off island, and seeing parts of the world that still exist such as the Flume in Franconia Notch, which my wife and I just did, help maintain some of the sanity we used to take for granted.

My current dreams. Sound proofing, softer ride for a passenger with a bad back, finishing up the 12 and 120 volt wiring and of course repairing all the various things which have been put off such as the DS electric window repair. (Using a temp boat pilot house drop window solution which works so well am tempted to just keep it as is.)

Anyhow, let us know what is happing and what you are planing.

Duncan

[ZsZ]

[Multiman mv]

Coqwesty, thanks for your comments. I guess I was happy that this mangled flying mess of metal and sunbrella didnt end up denting a large body panel. It could have been way way worse and oddly, I had a sense of calm come over me at the realization that I already got my first ding out of the way. I was parked in the same spot (you think I’d learn) just yesterday and this moped parked right next to me. I almost blew a gasket at the site as i went into a diatribe to my wife about how some jackass was going to walk by with a beach chair, hook the side mirror on the moped and tip the stupid thing over right into the van. My wife said, instead of giving this guy the hairy eyeball, just move the van over. Great idea, so i scuttled the van over a couple of feet, away from the moped and my blood pressure went back to normal. The tent incident did teach me to be slightly more proactive, choose your parking spots wisely (not that I chose wisely yesterday) but not to let it stress me out too much. My main reason for doing the paint job was to arrest the hands of time, and to stop any rust before it started to take hold. I still want to use the van and not have to worry too much about it.

Duncan, i must say that this corona thing has really put a hold on a lot of our travel plans unfortunately. Also, i almost feel like ive been cheating on miss pippen lately because after 6 years of being yard bound, we finally got our boat back in the water. Last weekend we motored over to cuttyhunk for the day to meet up with my brother for a sail on his 37 foot sailboat. A great day for sure and the boat has given us some safe travel alternatives lately.

I also have a couple small projects to take care of in the van before our next road trip. I have to redo the rear wheel bearings which were just replaced last November. Not sure why they failed but they are under warranty and new ones are in route. Also, i just ordered gowestys printed circuit board for the instrument panel. Since the paint job and the dash removal for the break booster, the gauges have been acting a little funny and ive narrowed it down to the foil. All i have to do is touch certain areas of the foil and the gauges react. Gowesty has been out of the printed boards but just got them back in stock.

You do bring up a good point about the thread and it being hard to find certain things. Some day, i will put together a comprehensive, chronological list of everything that has been done to the van and hopefully someone can find it useful.

Im sure we will soon resume our vanagon travels. We all miss it dearly though we have really been enjoying the van here on island. Just yesterday we parked at a beach on a blustery day, popped the top and watched a movie with the kids. Normally we use the van as a sort of base camp for their day at the beach and we are out surfing, fishing or just hanging on the beach, but this day we really had fun hanging inside watching a movie.

Hope your are well and glad youre getting out and about!

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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[Multiman mv]

So here is a comprehensive list of modifications, improvements and repairs that i have made to the van in case anyone wants a quick reference. I hope that some of you will find it helpful. Feel free to pm me with any questions, I’d be happy to answer any questions or help if i can. I will be adding to the list as time goes on and i still have a few more things to add at present.

Quick Reference Guide

-Replaced all fuel lines, fittings and resealed the fuel tank (Gowesty part#GVW FUELLINE and part# VANOTANK) 139A
-Gowesty 3 point seat belts for the middle jump seats (Part #: KT122J)
-Gary lee rear ladder and small luggage rack - http://www.vwrack.com/
-Rocky Mountain westy rear tire carrier and side ladder (part# RMW-TCSSDR01) and (RMW-LDR01)
-Third brake light, Gowesty part# 3RD-BRAKE https://www.gowesty.com/product/-/23669/third-brake-light-kit-led-?v=
-5 gallon road shower -older version - https://yakima.com/products/roadshower
-Yakima racks, towers, rain gutter attachments with round bars
-Gowesty all terrain 2wd suspension bundle (1.5 lift springs, fox shocks, gowesty alloys and BFG All terrain 215/70-16 tires) (part# Part #: GVW-WTP-1623-BFG)
-Gowesty South African grill and high power headlight kit (Part #: GVW-WR2-SA)
-Addco front sway bar from Andys Auto Sport - https://www.andysautosport.com/shopbybrand/addco/volkswagen_vanagon.html
-Burley Motorsports end links (SKU: 251 411 051 A)
-Eurospec brush guard from van cafe
-Arb 2500 8’x8’ awning and side tent
-Foreign Auto and Supply 1.9 pd tdi engine conversion http://www.foreignautosupply.com/
-Manual transmission regear new ring and pinion (4.14) new 3rd and 4th gears (1.18 HD, .77HD) Peloquin limited slip differential (FAS)
-Kennedy stage II clutch - https://www.kennedyeng.com/clutches
-Burley upper control arms (SKU: 251 407 047B)
-Gowesty new generation bigger front disc brakes (part# Part #: GW-V-BIGGER-BRAKES)
-Eberspacher D2 diesel heater
-Dynamat extreme sound insulation and dynaliner heat insulation on all body panels, headliner and doors. 1/2 inch Dynaliner heat insulation where room permitted.
-Stainless steel coolant pipes - Gowesty (Part #: 251-121-397SS)
-Scan gauge II
-Westy lounge hardware from Boxeer https://www.boxeer.com/products/westylounge-rear-bench-kit-vanagon-free-worldwide-shipping
Replacement lcd clock screen, Gowesty - Part# GVW-CLOCK-LCD-KIT https://www.gowesty.com/product/light-fixtures-parts/24626/replacement-lcd-screen-for-clock?v=
-Alpine Bluetooth stereo, Alpine 100 watt amp and Boss audio subwoofer
-Morel 4 inch speakers front and rear
-Spot trace gps tracker located....
-ProSport 20 battery charger (gowesty Part #: GVW-PRO-V3)
-Gowesty auxillary battery isolator kit (Part #: AUX-701)
-Gowesty lifepo4 auxillary battery (Part #: GW-LIFEPO)
-Pyle plcm4375wir wireless backup camera
-Stainless u joint for shift linkage from RsFab - http://rsfabparts.com/product/new-product-5/
-100 watt flexible solar panel and zamp solar 10 amp charge controller from Gowesty - Part #: ZS-10A-GW
-T3 technique shift knob - http://t3technique.com/
-Gowesty dual wiper nozzles (Part #: 211-955-993D)
-Gowesty programmable intermittent wiper relay (Part #: 3B0-955-531)
-Gowesty 3 point seatbelts for bench seat (Part #: KT122-VANO)
-Blue led bulbs for dash and instrument panel
-Gowesty led exterior light kit (Part #: GVW-LED-EXT-VANO) https://www.gowesty.com/product/electrical-electronic/23624/exterior-led-bulb-kit-?v=
-Replaced all interior lights with leds from gowesty
-Footwell lights from Vanagon Leds - https://vanagonleds.com/
-Buslab steering column cover with seat heater knockout - https://www.buslab.com/product-p/251953515a01c.htm
-Keynice temperature gauge for steering column - https://www.amazon.com/Keynice-Thermometer-Tempera...ooghydr-20
-Additional gowesty, 20 amp 12 volt socket in dash - Part #: GVW-181399
-Rocky Mountain Westy locking drawer below passenger seat (part# RMW-LSD01PA) https://www.vancafe.com/RMW-LSD01PA-p/rmw-lsd01pa.htm
-Vanagon life center console with additional cup holders - https://www.vanagonlife.com/vanagonshop/locking-steel-center-console
-Recaro leather seats sourced through 425 Motorsports - https://www.425motorsports.com/recaro-expert-s-seat.html
-Leather door panels from Sewfine
-Terrawagen Black molded door kick plates https://www.terrawagen.com/products/vanagon-inner-door-kick-panel
-Gowesty lift assist poptop springs (Part #: GW-V-POPTOP-LIFT)
-Gowesty replacement skylight kit (Part #: GVW-255-745)
-Burley 930 cv and axle kit (SKU# 251 501 203G-930KIT)
-16” Carat alloys from Van Cafe
-Aluminum center caps from T3 Technique - http://t3technique.com/lug-nuts-studs-and-bolts/wheel-accessories/custom-center-caps-(shallow)/
-Gowesty Alternator charge initiation kit (part# ALT-100) - https://www.gowesty.com/product/-/24031/alternator-charge-initiation-kit?v=
-Ceramic coating on exhaust pipes from turbo to muffler from JetHot corp - https://www.jet-hot.com/
-New steering rack from Van Cafe - https://www.vancafe.com/251422061-p/251422061.htm
-Lemforder upper ball joints
-Cosmoline sprayable amber wax “Rust Veto” under coating applied once a year https://www.cosmolinedirect.com/?gclid=Cj0KCQjwwOz...zkEALw_wcB
-Silicone steering rack Boots from Alika Motorsports
-Gowesty window seal kit (Part #: GVW-253-811)
-Front window seal kit, Gowesty (Part #: ROLLUP-RESEAL)
-Bus Depot replacement front wing window frames (part# 171837658)
-Windows out, Orly Blue paint job By Reflections Auto Restoration, Harwich Mass. - https://www.reflectionsautorestoration.com/
-BMW Brake Booster (part# 34331157416)
-Gowesty new generation rear disc brake kit (Part #: GW-V-REAR-DISC)
-Rocky Mountain Westy front and rear twin peaks bumpers - https://www.vancafe.com/RMW-8000703-p/rmw-8000703.htm
-Gowesty printed circuit board for instrument panel (Part #: GVW-255-919-059) https://www.gowesty.com/product/-/24189/replacement-kit-for-printed-circuit-foil-?v=
-Gowesty shifter system overhaul bundle - https://www.gowesty.com/product/bundles-and-kits/24174/shifter-system-overhaul-bundle-?v=
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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[DuncanS]

Wow, Nick--Thanks for all the mod info. That must have take a fair amount of time to just list everything. Didn't mean to have you spend so much time doing it, but thanks and I'm sure everyone else will appreciate it as well.

I've been able to do a fair amount of travel/camping lately and it has been great. In fact we just got back home today after a mini trip up north. In late spring when it became clear that I wasn't going to put my boat in the water, I felt the urge to smell some ocean and see some boats so drove over to Camden, Maine for a couple of days. Never got out of the car except to visit kids and friends from 10 feet away while wearing masks. (Except see below.) Took food with me.

Did have one experience which might be helpful to some. Rained hard on the way over and coming into Camden, the car started to buck and the fuel pump been making noise for a while before that. Was going to call the guys at FAS, but my daughter knew of a Vanagon guy in Belfast. It's called the Beetle Shop and the guy was super. With no appointment, he dropped everything to get me back on the road. For anyone finding themselves in the area, I recommend him as he definitely knows what he is doing. In one of his bays, he was converting an air-cooled tiptop into a WBX pop top. Car had been stripped and perfectly painted inside and out. I had just replaced the fuel pump, but luckily the mechanic said I had a no-name brand. He has had a bunch of trouble lately with Bosch and said don't buy them. The problem turned out to be failed grommets at the roll-over valve in the gas expansion tanks behind the wheels. The tires threw up water which then got into the system. He didn't have any spares, but bypassed the tanks until my BD units arrived which I installed back in New Hampshire. He said this is an often overlooked maintenance problem and they should be replaced about every three or four years. He drained out all the water and replaced the filter. He recommends another filter ahead of the pump too. So add this to your list everyone.

Duncan

[Abscate]

Missed you by a week at Cuttyhunk. Might be there weekend of Sep 12.

No obnoxious NYrs last time



Here’s how we get on Island...usually from Horeseneck Beach inWestport

Tow vehicle in front, T4, water vehicle in back,...M26

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.ssS!

[Multiman mv]

Abscate, I was going to drop you a line to see if you were around but our day was pretty jammed pack. Could definitely try in September. Hoping my next home build doesn’t start for a few more weeks. Construction permits have been slow coming these days.

Duncan, no problem it really didn’t take that long and we had a rainy day yesterday so it was perfect. I had been meaning to do this for a long time so I’m glad you brought it up. If one person benefits from the list then it was well worth the time. If I get inspired, I’ll put the page numbers where mods can be located in the thread to make it easier to reference things.

I’ve been to the Beetle shop in Belfast (they were closed at the time) and saw the grey Syncro tin top that was for sale (for sale again and listed on the samba.) it looks like they do great work. Glad he was able to help you out. I’m going to say that there was probably a zero % chance that someone not well versed in vanagons could have pinpointed that problem. I would have thought O2 sensor or vanagon syndrome/allrflow meter or something but would have had a hard ten zeroing in on the issue that you had. Glad you got it all sorted out.

We’ve been dying to get off island for a trip but this week three steamship employees tested positive for corona and they’ve cancelled man boats because of it. Still hoping for a trip in September. Will have to wait and see.
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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[snwbrdr435]

[Multiman mv]

So i have been experiencing some grinding noises from the rear wheels and as it turns out, the rear wheel bearings that I replaced last November both crapped out on me. Not sure what caused this but im hoping it was just bad parts and not my housings. If it happens again, ill start to consider the housings. Stub axles look to be in good shape. The parts were still under warranty so I was able to get a set of replacement bearings. After replacing the bearings the noise is gone so Im good for now, back on the road after a quick 4 day hiatus. Im sure i could have driven the van but didnt want to cause any more possible damage.

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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[big swifty]

After I replaced a second rear bearing that again crapped out, I bit the bullet and replaced the housing. Most likely that is your problem.
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Evan
1987 Vanagon Syncro // Westfalia pop-top graft // Factory new ALH. 11mm IP. AFN 110 RC 2,3,4 // S7 turbo// Titan P502's
2013 Golf 4d TDI. No mods. Yet.
[1991 Jetta coupe TD. Giles Superpump. Custom tall 5 speed. SOLD

[Multiman mv]

[Multiman mv]

Took the van to the local pop up drive in last night with the kids. We ended up in the cheap seats because it was sold out so they placed us off to the side. It ended up working out great because when we popped the top we could see over the string lights that were in front of us. My buddy parked next to us with his toyota Hiace fire truck. A very Doka-like vehicle. He ended up finding it in Seattle for 12k with 9000 miles on it. I’ll post a photo when I can.

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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[Multiman mv]

This is an exact representation of my buddy’s Hiace, though he just put on new 15” wheels and bfg’s and gave it a little lift.

So it turns out that this was the original for sale ad of my buddies Hiace that i happened to find off of the internet. Here’s his truck today with the new tires.

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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[Abscate]

Aiming at Cuttyhunk next weekend. I’ll pm you Mt details, I’m a bit worried about resupplying during Covid
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.ssS!

[Multiman mv]

[Multiman mv]

I got around to replacing my old blue foil circuitry with the gowesty printed circuit board. So thankful we have a company that is putting out fixes and improvements like this. My blue foil somehow got fried (everything worked fine before paint but when I got the van back the dash lights didn’t work, the tach wouldn’t work with the brights on and the fuel gauge was off. After the install of the pcb everything works as it should.

Now there’s the problem

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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

[DuncanS]

Hey! You even have a working digital clock! I can't ever remember mine working in any of my T3's.

I'm toying with the idea of black on white gauges. Have you ever run into anyone with that or who could do it?

D

[Multiman mv]

[Multiman mv]

Also, I did buy a new lcd display for the clock A while back. my original crapped out but I really liked having the clock. i just added that one to my master list of parts and mods.
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1991 multivan, FAS 1.9 tdi, Peloquin limited slip
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0