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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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 Posted: Wed Dec 23, 2020 8:52 am Post subject: Introducing an old friend, 1984 Westfalia |
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This is not a new acquisition, it's been in my care since about 1996. During that time, it's had it's up and downs. Always seemed to be star crossed with cooling problems. I suppose that's the weakness of them all though.
I'm going to start out with a few flashback pictures, sadly, the oldest ones are probably lost to the 35mm film grave. I should be able to get uptodate quick enough, it's back on the road and giving us joy.
These are from about 2014.
I about 2015, I let my mother take it on a weekend trip with the FMBC. On the way home, something broke and the original 1.9 came to a halt. After cooling down, it no longer rotated. I had my 13 Y/O son help me pull the engine out.
No need to guess the problems, at this time, I know what it was.
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Imagine that, theres not an "h" in either Westfalia or Syncro? |
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cmayna
Samba Member
Joined: August 18, 2014
Posts: 1147
Location: SF Bay area, CA
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| Posted: Wed Dec 23, 2020 9:10 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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Such fond memories..........
How is it running now?
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'90 Westy / automatic.
If I'm not working on the camper or my '50 Chebbie truck, I'm either fishing with the wife or smoking Salmon.
Craig |
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Fri Jan 08, 2021 10:03 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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Since the engine was seized, I thought a "running" 1.9 would be the quick way. After buying one and getting it home, I didn't do so well. I bought one from a Subie swap, so it came with many spare parts. I should have inspected it closer, but I guess I was too impatient. It had been leaking all around the water jacket and head nuts.
I have a few pictures of the engine assembly. It was a cheap refresh, just enough to get running again. I didn't split the case, but changed the rod bearings. I figured standard for standard on a worn crank should have enough clearance. It may break, but I'm already planning on a 2.1. New rings on the original P/C's, hand lapped valves and a gasket kit.
One of the heads before clean up.
This is how I surfaced the head.
Afterwards, I think The Right Stuff should fill in the divots.
You get excited when you get this close.
Yes, assembled
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?Waldo?
Samba Member
Joined: February 22, 2006
Posts: 9752
Location: Where?
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| Posted: Fri Jan 08, 2021 10:13 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| The 'head gasket' is pinched between the head and water jacket of the case. The amount of pinch is set by those two surfaces and the height of the cylinders where they are inserted into the head. When you remove material from the cylinder head surface or the water jacket surface without changing the depth that the cylinder inserts into the head then you reduce the pinch on the gasket. Hopefully it is not affected enough to make a difference in the long term sealing of the gasket. |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10367
Location: Sunshine Coast B.C.
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| Posted: Fri Jan 08, 2021 12:25 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| ?Waldo? wrote: |
| ... When you remove material from the cylinder head surface or the water jacket surface without changing the depth that the cylinder inserts into the head then you reduce the pinch on the gasket. Hopefully it is not affected enough to make a difference in the long term sealing of the gasket. |
If amount of "pinch" was reduced, will the layer of Right Stuff, as buspor63 planned to apply, help keep gasket in place? (or in place for more miles)
@buspor63
Morbid curiosity, but what went wrong with the original 1.9 ? Rod?
It appears you are resealing/refreshing the recently purchased 1.9
Looks like those heads had low miles after previous reseal was done.
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Fri Jan 08, 2021 2:40 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| Vanagon Nut wrote: |
Morbid curiosity, but what went wrong with the original 1.9 ? Rod?
It appears you are resealing/refreshing the recently purchased 1.9
Looks like those heads had low miles after previous reseal was done.
Neil. |
The original engine was being driven by someone inattentive when it lost coolant. It was driven till is seized, probably smeered the pistons. I initially thought it was the right side heater hose that failed, but later, I saw where a head stud broke.
I'm not too concerned about the amount of material I may have removed, I used 320 and a good glue to seal it all up. In my two stroke racing days, we always lapped heads on mirrors to make sure they we flat. I feel confident that a good glue joint will keep it sealed.
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?Waldo?
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Joined: February 22, 2006
Posts: 9752
Location: Where?
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| Posted: Fri Jan 08, 2021 3:11 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| I have also hand lapped many cylinder heads. However, with virtually every other cylinder head, the removal of material from the head sealing surface does not affect the squish of the gasket like it does with the WBX. It's apples to oranges. Hopefully it works out for you. |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10367
Location: Sunshine Coast B.C.
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| Posted: Fri Jan 08, 2021 5:07 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| buspor63 wrote: |
| Vanagon Nut wrote: |
It appears you are resealing/refreshing the recently purchased 1.9
Looks like those heads had low miles after previous reseal was done. |
I initially thought it was the right side heater hose that failed, but later, I saw where a head stud broke.
I'm not too concerned about the amount of material I may have removed, I used 320 and a good glue to seal it all up. In my two stroke racing days, we always lapped heads on mirrors to make sure they we flat. I feel confident that a good glue joint will keep it sealed. |
A buddy of mine had a head stud snap on his 1.9 while far from home. IIRC, the "to get you home" repair was to thread and plug the stud hole. This repair actually lasted a relatively long time.
Thanks and yes, was curious grade of paper used.
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Mon Jan 18, 2021 6:48 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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Putting the engine back together, I knew I had trouble with the exhaust studs. I thought it would be better to tackle once assembled since it wouldn't move arounds as much.
The double nut technique failed so I decided to weld nuts on what was left. It worked, but brought some of the aluminum out with them. Fortunately, I had some Time-Sert's. I really like these for damaged threads.
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ALIKA T3
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Joined: July 30, 2009
Posts: 6347
Location: Honolulu,Hawaii and France
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| Posted: Mon Jan 18, 2021 12:35 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| ?Waldo? wrote: |
| I have also hand lapped many cylinder heads. However, with virtually every other cylinder head, the removal of material from the head sealing surface does not affect the squish of the gasket like it does with the WBX. It's apples to oranges. Hopefully it works out for you. |
Don`t worry about it, the rubber gasket compresses enough.
I saved some super pitted heads with JB weld and I lapped them with a belt sander, Pakistanese style  . If the sealing surface for the o`ring is good, and the fire gasket, it will be good.
I too use the Right Stuff Black, I coat the water jackets with my finger, then put the gasket then coat the gasket with my finger so it`s even on the whole gasket, not just a bead out of the cartridge spout.
Many years later, zero leak, daily runner, almost 50K on the clock.
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10367
Location: Sunshine Coast B.C.
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| Posted: Mon Jan 18, 2021 2:22 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| buspor63 wrote: |
... I knew I had trouble with the exhaust studs. ....
The double nut technique failed so I decided to weld nuts on what was left. |
Did you use a 110 VAC MIG on those nuts to studs?
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
VE7TBN |
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Tue Jan 19, 2021 9:05 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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Did you use a 110 VAC MIG on those nuts to studs?
Neil.[/quote]
Maybe, are you going to make fun of my welds? 
I had oxy-acetylene, would that have been better?
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Vanagon Nut
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Joined: February 08, 2008
Posts: 10367
Location: Sunshine Coast B.C.
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| Posted: Tue Jan 19, 2021 10:54 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| Vanagon Nut wrote: |
| Did you use a 110 VAC MIG on those nuts to studs? |
| buspor63 wrote: |
Maybe, are you going to make fun of my welds?
I had oxy-acetylene, would that have been better? |
lol. No, not making fun. Was just curious for future reference should I ever need to do that trick. I have a 110 MIG so was wondering if it would properly penetrate a nut to a stud. Thinking now, I bet it would.
Neil.
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1981 Westy DIY 15º ABA
1988 West DIY 50º ABA
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Abscate
Samba Member
Joined: October 05, 2014
Posts: 22639
Location: NYC/Upstate/ROW
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| Posted: Wed Jan 20, 2021 5:34 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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You can pretty much do anything automotive with a 110 MIG, with added patience. Actual weld time is a tiny fraction of bodywork time, it’s all in the prep.
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Wed Mar 24, 2021 9:11 pm Post subject: Re: Introducing an old friend, 1984 Westfalia |
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I'm about six months behind on updates
Most all of the bits back on
Home sweet home
Everybody has a bong, right?
I had the initial lifter clatter, but it didn't go away. I've had it before, so I knew where to look. One of the push rods had popped out, I guess when a lifter is really down? Put it back in, and all was good.
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Sun Jun 13, 2021 8:33 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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The refurb is going well, several regional trips successfully done.
The blower motor didn't work. I really didn't think it would, it hasn't worked since I bought the Westy in 1996.
While the heater was out, I put some KilMat under the dash. I also replace the motor resistor with the Jeep Cherokee one, I even used the Jeep harness from a salvage Cherokee.
Yeah, that's probably going to keep the flaps from working.
The motor was a total meltdown.
This foam was shot. I replaced it with headliner material from Jo Ann Fabrics.
The Jeep resistor is a good "upgrade" At least when it fails, it's easy to replace.
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Fri Jul 30, 2021 6:18 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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So, I've grown tired of posting rebuild photos. Let's share some fun photos.
Early summer trip to Hot Springs NC. Being from Knoxville TN, it's not too far.
First real view of the mountains after leaving Newport TN.
Downtown Hot Springs NC. Local brewery is Big Pillow. Sadly, there are no public hot springs, only commercial ventures. The pump the water into hot tubs alongside the French Broad river.
We camped at Rocky Bluff NFS campground just out of town.
The following day, we drove gravel to get to Max Patch. Even though I'm local, this was the first time I've been there.
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brickster
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Joined: January 05, 2004
Posts: 512
Location: CO, USA
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| Posted: Fri Jul 30, 2021 7:49 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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We have the same year/color. Looks like a fun trip!
Did you add the snazzy door bumper strip?  |
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Fri Jul 30, 2021 11:36 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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| brickster wrote: |
Did you add the snazzy door bumper strip? |
No, I think it was dealer added. The vinyl is shrinking, once it becomes enough of a concerne, I'll see if a trim shop can replace just the vinyl. The aluminum is riveted on.
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buspor63
Samba Member
Joined: February 17, 2005
Posts: 1179
Location: Knoxville,TN Where America stops for gas
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| Posted: Wed Nov 03, 2021 7:28 am Post subject: Re: Introducing an old friend, 1984 Westfalia |
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I'm pretty slow at updating. I've left out a lot of other "work" type photos too.
I did put KilMat on the side slider, I feel that it was an improvement. The original, long outside handle had broken, so it was open. The replacement handle came from Bus Depot. It's the new version with the different lock type. I just swapped my old lock set in, works great, still all matching keys.
This mid summer trip was to North Carolina. We went to Tsali to camp and ride bikes, then just a short bit to the Nantahala Gorge to hang out by the cool waters of the Nanny. After that, it was tourist time in Bryson City.
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