1981 Vanagon Westfalia

Ninz306 · Posted: Mon Dec 30, 2024 2:33 pm Post subject: 1981 Vanagon Westfalia

Hello everyone,

I wanted to say hello and introduce my VW Vanagon. It currently has the original 2.0 air cooled engine. I bought it non running from a local guy in town. It originated from Yuma, Arizona and was last registered in 2013.

I’ve replaced the canvas top, recoated the fiberglass, replaced the front seats, replaced the upholstery and foam on the bottom bed, rebuilt the axles, full tune up on the engine, new tires, and a few other things. I’m currently replacing the gas tank for the second time and rebuilding the shift linkage bushings.

My future plans are to do a Subaru swap. I’m currently calculating the cost. I’ve already purchased a suitable donor vehicle. I wanted to go k24 swap, but the Subaru made itself available before any Honda.

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JohnL99 · Posted: Mon Dec 30, 2024 3:32 pm Post subject: Re: 1981 Vanagon Westfalia

Twins! Started as a 1980 air cooled. I did a E25 Sub also. We use this thing all the time. Congratulations!

Ninz306 · Posted: Mon Dec 30, 2024 4:48 pm Post subject: Re: 1981 Vanagon Westfalia

JohnL99 · Posted: Mon Dec 30, 2024 5:03 pm Post subject: Re: 1981 Vanagon Westfalia

space · Samba Member Joined: November 19, 2017 Posts: 809

I did the subie swap on my 82 2.0
Worked well w/o the lower grill cutout
However I did end up doing the lower grill (for aesthetics as well better airflow)
_________________
82 westy
w:
2.5 JDM Subie
Rear discs

Ninz306 · Posted: Mon Dec 30, 2024 8:18 pm Post subject: Re: 1981 Vanagon Westfalia

Ninz306 · Posted: Mon Dec 30, 2024 8:23 pm Post subject: Re: 1981 Vanagon Westfalia

Ahwahnee · Posted: Mon Dec 30, 2024 9:06 pm Post subject: Re: 1981 Vanagon Westfalia

You don't say where you are in the Grand Canyon State... but here's an interesting air-cooled to Suby conversion that was done by an acquaintance here in Tucson:

https://www.thesamba.com/vw/forum/viewtopic.php?t=700449&highlight=

Ninz306 · Posted: Tue Dec 31, 2024 10:16 am Post subject: Re: 1981 Vanagon Westfalia

Ahwahnee · Posted: Tue Dec 31, 2024 4:01 pm Post subject: Re: 1981 Vanagon Westfalia

I'll ask (his father) next time I see him. They are both very savvy automotive guys so I think it likely they've got it to work. If it works in Tucson it should work anywhere.

Ninz306 · Posted: Wed Jan 01, 2025 1:27 pm Post subject: Re: 1981 Vanagon Westfalia

Ninz306 · Posted: Thu Jan 23, 2025 8:13 am Post subject: Re: 1981 Vanagon Westfalia

I was able to do an axle shaft rebuild. Two of the boots were in bad shape. This is pretty straight forward job. Clocking them is the only real thing I had to be sure I did right.

Ninz306 · Posted: Mon Jan 27, 2025 1:36 pm Post subject: Re: 1981 Vanagon Westfalia

One of the things I don’t like about my vanagon
Is the design of the gas tank and the expansion tanks.
IMO the plastic pieces and rubber grommets will inevitably fail.
I live in a very hot arid environment, so I opted to purchase a new tank
and weld threaded bungs. I then threaded in brass fittings.
I fabricated a plate with threads in order to install a more modern
Fuel sending unit. The replacement fuel sending units are trash and often
Require adjustment so they won’t leak. I proceeded to pressure test the tank after everything was welded and painted. I simply plugged the hoses and poured soapy water over all the fittings and the fuel sensor. Happy to report that no leaks were detected.

4Gears4Tires · Posted: Mon Jan 27, 2025 2:38 pm Post subject: Re: 1981 Vanagon Westfalia

That looks awesome. Nice work.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition

Ninz306 · Posted: Mon Jan 27, 2025 9:19 pm Post subject: Re: 1981 Vanagon Westfalia

Ninz306 · Posted: Mon Feb 10, 2025 5:10 pm Post subject: Re: 1981 Vanagon Westfalia

I was able to finish the install of the shifter bushings. The van was having a
hard time shifting into first and reverse. There was also a screeching sound from the absence of a center rubber bushing. I replaced the shift tabs and did a shifter rebuild kit (parts not pictured).

I found out how imperative it is for the two connecting shift rods to mate exactly the same way they come apart. Mine were off by about 1/16 and my van refused to shift into reverse. I did mark them with a punch before removing them, but i figured the slight offset would be negligent. It wasn't.

Lastly the tank went in. The fuel sending unit has a different Ohm reading than that of the current gauge. This is because I will upgrade the gauges with Speedhut gauges in the future. The fuel sending unit corresponds with the Ohm reading for a speedhut gauge.

I will be running an aftermarket gauge for now. I utilized the same wires for the new fuel sending unit to avoid running new wires through the van. I also installed a disconnect plug for the sending unit in case I need to service the tank again.

bobbyblack · Posted: Mon Feb 10, 2025 6:12 pm Post subject: Re: 1981 Vanagon Westfalia

I'm not sure on this, but the fuel tank 'saddle' might take the vent tube going up and over the various other bits, rather than under. Just from what instructions I've followed in the past.
_________________
'87 Westy 'Flossie','86 Westy 'R1','86 tintop GL - Subi2.2 'J2','83.5 stock tintop L 'ZoomBus','74 Karmann Ghia, '63 Notch

GoEverywhere · Posted: Mon Feb 10, 2025 6:26 pm Post subject: Re: 1981 Vanagon Westfalia

Ninz306 · Posted: Mon Feb 10, 2025 9:45 pm Post subject: Re: 1981 Vanagon Westfalia

GoEverywhere · Posted: Mon Feb 10, 2025 9:47 pm Post subject: Re: 1981 Vanagon Westfalia


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