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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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 Posted: Fri Oct 25, 2024 6:27 am Post subject: Re: In for a penny, in for a pound |
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Unfortunately I removed the short piece of hose that connects to the faucet and while I tried to be gentle, it crumbled. So while I don't have a lot of confidence this fix will last a long time, I am hoping it will last for a little bit. If it doesn't hold the water pressure, I will remove the faucet and create a more permanent fix.
And I very gently tightened this hose clamp. I really wanted to cinch it down but I figured the remaining plastic nub would just collapse.
I used some spray glue to add a piece of insulation to the bulkhead for the water tank, like OEM
I wiped down the water tank, inside and out with clorox.
I went back and forth on how to approach this repair. I really considered just wrapping the individual wires with electrical tape and then heat shrinking the area, or cutting and repairing. I decided on cutting and repairing because electrical tape just isn't a permanent solution, imo. Even if it's heat shrinked on top.
I filled the tank up and used a jump pack for 12v power. The pump works!
I stopped in the middle of electrical work for dinner. But one more cabinet is in place.
Hopefully by this weekend the interior will be back together. And the dash can come out.
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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Sodo
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Joined: July 06, 2007
Posts: 10636
Location: Western WA
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| Posted: Fri Oct 25, 2024 7:23 am Post subject: Re: In for a penny, in for a pound |
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There are lots of replacement Westy Delta6 faucets around if you keep an eye out.
I got a real nice one from a member who did a popular “upgrade”
(functionally but not “Waesthetically”) 
Sometimes the switch inside is broken.
Don’t discard yours, you may need the switch parts.
I’ve wondered if the switch would work more reliably if switching the pump motor thru a relay.
Which is a real easy mod (on my list).
I need to tear my kitchen apart to fix westy kitchen rust.
Then the dash…..
_________________
'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb |
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Crooked Designer
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Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Fri Oct 25, 2024 7:51 am Post subject: Re: In for a penny, in for a pound |
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I hope you’re considering deleting the city water hook up. They leak at the back of the hookup box frequently (even with a pressure limiter) and dump water into the insulation you just put in. That sits wet for eternity and rust is inevitable. Ask me how I know. The T check valve also leaked in my van. Just a disaster of a system in my opinion. I deleted and put a aux solar hookup in its place and have never missed the water hookup. Would hate to see all that beautiful work behind the cabinets get soaked.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Fri Oct 25, 2024 1:18 pm Post subject: Re: In for a penny, in for a pound |
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The switch in the faucet works! I would have tested it with water by now but the drain pipe keeps cracking and breaking. Off to home depot.
Interesting comment about the leaking city water hookup. It would take awhile to find out and by then, a lot of water will have soaked into the cabinets. Thanks, I'll consider it or maybe a water to monitor.
Relevant to the city water, I discovered that one of the gnaw marks went through the pipe. Looks like I'll cut the entire gnawed section out and splice in something.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Sun Oct 27, 2024 7:15 am Post subject: Re: In for a penny, in for a pound |
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| Crooked Designer wrote: |
| They leak at the back of the hookup box frequently (even with a pressure limiter) and dump water into the insulation you just put in. |
I owe you a beer. 
Everything was just so dirty. 40 year clean out, I guess.
Cleaned up. I used Purple Power and a scrub brush, then wiped it down. Then cleaned it again with a Clorox/lemon scent spray, and wiped it down again. It seemed to work well and smell better than the Purple Power.
So on to fixing the City water line. Their internal diameter has to be 3/16s, not 1/4. The 1/4 to 1/4 barbs I bought would not go in easily and the plastic does not have a lot of play. But after much struggle, I finally got the barb in 3/4s of the way, enough for me. Then I tried to put the fitting on (backwards in this photo) and.... yeah it doesn't go past the barb. So cut it off and try again...
I chucked the barb in a drill and laid it against the workbench with some sand paper to reduce it's OD.
I then used my heat torch to heat up the brass fitting and jammed the tube on as far as it would go. If you think maybe you should heat the tube, not the barb, you would make the same mistake I did. The tube becomes floppy and does not shove down far enough. 3 out of 4 barbs, good enough. I tried to hammer it further into place, but once the brass cooled it's jammed in tight. Won't budge.
I did the same process with the faucet side, however I kept the barb chucked in the drill and I spun it and pushed it into the hose after heating it. This was the way to go and it's at full depth. The 1/4 line, designed for these barbs, easily slides in place and seals properly. I really would have liked to add 1/4 Oetiker clamps for that 200% reassurance, but unfortunately they aren't stocked at my local HD and I didn't have any in my basement stock.
Because I am impatient I didn't paint and redo the graphics on the cabinet like I meant to. I want to get this van on the road. So it'll be a future project. But the LEDs work!
And I have water from the tank and from the city water connection!
Because of Crooked's comment, I kept an eye on the junction. Yep, it leaks.
Removed the brass fitting, added pipe dope, then added it back. No leaks.
Just the fridge and the tank lines to go.
Gave the tank some wire wheeling, sanding with 60 grit, and a wash. I'll give it a quick spray bomb and it'll go back on the van.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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dobryan
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Joined: March 24, 2006
Posts: 17140
Location: Brookeville, MD
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 10636
Location: Western WA
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| Posted: Sun Oct 27, 2024 8:39 am Post subject: Re: In for a penny, in for a pound |
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I’m with DOB. I’d use the city water with a hose to periodically fill my tank in that case.
While searching for a more remote site,
praying that I’m not stuck there too much longer.
15 gallons lasts us 3-5 days, perhaps more.
We generally only run out if we forgot to top off before departure.
I’m not sure what I’d put in that access box, probably an SAE connector.
I wonder if theres a double SAE outlet.
One for charging (to start battery)
and other for aux power output (from House battery).
_________________
'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb |
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dobryan
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Joined: March 24, 2006
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Location: Brookeville, MD
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Mon Oct 28, 2024 4:55 am Post subject: Re: In for a penny, in for a pound |
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Yeah, I definitely don't do KOA style campgrounds, and even if I had an emergency and needed one, not sure why I wouldn't just use the hose and tank. Although, I suppose it saves the battery slightly. Once this van is on the road, a house battery will be installed and then an SAE connector makes sense to charge up the house battery.
First thing I did was spray paint the tank and cover. Dumped about a whole can on it.
While that was drying in the sun I went to the headbanger cabinet. A 10' roll of foam gasket is just enough for the AC blower motor plenum, I think I had 3" left over.
Super precise hand rips. Haha.
I fought reinstalling all these cabinets a lot. There is a super specific order of operations for installing them. All brackets should be loose and then everything is connected, then tightened. Having one side tight means you will not be able to shove everything over to get the bolt through the other hole.
So after trying to shove the headbanger over and failing I went to untighten the top bolt. Well, like the other side, it just stripped in the wood square and rotated. Not wanting to take the cabinet down, which was a pain to get up and bolted in the first place, I dremeled a slot into the end, then did the screw and wrench trick again to loosen it. PITA.
Also a giant PITA? Reinstalling this fridge. It's not even that there is no free space to install it, there is negative space. I have no advice, just keep 'rasslin it.
Flue on
And again, the order of operations. These pipes need their cover before the tank goes in. I was annoyed until I figured I can probably just lower the tank to the ends of the bolts and then get in there.
Which gave me just enough space. I hate having to disconnect and reconnect the gas lines. I figure the more times it happens, the higher potential for a leak.
Plate in, lines connected, tank in, cover on, good to go here.
More order of operations stuff. This little cover plate was giving me grief on install. Blocking the whole bench from getting into position. No problems on removal though. Anyway, removed that cover, bench went into place. Antiseize on the bolts into the chassis of course. I bought a fresh can of anti-seize just for the reassembly of stuff on this van.
And then put it back! I need about a billion of the little brown screw covers.
And it's back together!
Fridge is still working on 120, will need to check DC and propane.
Guess the bonus.
On to the dash.
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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Crooked Designer
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Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Mon Oct 28, 2024 7:04 am Post subject: Re: In for a penny, in for a pound |
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| 4Gears4Tires wrote: |
| Crooked Designer wrote: |
| They leak at the back of the hookup box frequently (even with a pressure limiter) and dump water into the insulation you just put in. |
I owe you a beer.
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Great solve for the back of the hookup box. Don't know why I never thought of that.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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Crooked Designer
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Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Mon Oct 28, 2024 7:16 am Post subject: Re: In for a penny, in for a pound |
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| 4Gears4Tires wrote: |
Which gave me just enough space. I hate having to disconnect and reconnect the gas lines. I figure the more times it happens, the higher potential for a leak.
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I used yellow thread sealing PTFE tape. When I swapped out my Dometic for T49, I installed a new gas line in place of the dometic fridge to use for my Propex. Cleaned all the gunk off the old brass fittings with a wire brush and steel wool. Flared a new line, taped everything and reconnected. No leaks and I never worry about it.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Thu Nov 07, 2024 6:50 pm Post subject: Re: In for a penny, in for a pound |
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Well I took a bit of a break. Work got a bit busy and I didn't feel like I had the energy to get at the dash. I know it's not that bad, but it just feels a bit overwhelming.
First off. Fridge has been running on 120 for two weeks. Looking good.
So on to the dash. Wheel off, cluster out. So far, so good.
I actually got the other one removed without breaking it. I tried so hard. Pushed from the back and pried from the front. Nope. Still broke. Such a silly design.
Now on to this antique that has to be fairly close to the age of the van itself.
I some how remembered that these remove by pulling the knobs off. So I started there.
And one plate off.
And two plates off. and how does this 3rd plate come off? What the crap.
Called around a bit because the internet was no help. Pry it off was the suggestion i went with. Three plates off now.
Should finally be free! Just kidding. there is a 10mm nut on the back. Got it removed and saw that the power wire was chewed in half, that is why it didn't turn on.
These harbor freight bolt extractors have to be one of the best tools I've ever bought there.
Unhooked the amp and got the dash out. It's so dirty under here. 
And so many wires are chewed.
I called it a day and walked away.
On the upside, my lovely girlfriend bought me a key ring for the van for my recent birthday.
I think my plan is to repair all the wiring, then start cleaning, then remove the box. Right now, most of the chewed wiring is laying end to end making it easy to trace.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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dobryan
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Joined: March 24, 2006
Posts: 17140
Location: Brookeville, MD
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Crooked Designer
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Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Fri Nov 08, 2024 9:29 am Post subject: Re: In for a penny, in for a pound |
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| 4Gears4Tires wrote: |
I think my plan is to repair all the wiring, then start cleaning, then remove the box. Right now, most of the chewed wiring is laying end to end making it easy to trace. |
FYI - there is an error in the Bentley wiring diagram for the 1985 westy. A fuse is mis-numbered in the diagram and it caused me to run around in circles on a wiring project a few years ago. I can get that to you if you’re interested. I have it marked in my Bentley, but can’t remember off the top of my head exactly where it was. Of course my Bentley is in my van in storage right now, but I’m probably taking it out to “winterize” this weekend.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Tue Nov 12, 2024 9:36 am Post subject: Re: In for a penny, in for a pound |
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Thanks, but I am hoping I am just connecting wires, not figuring anything out. If that changes, I will send you a message.
The speaker wire just came in pieces and I couldn't find where it had been chewed. So I figured, well there has to be at least one spot to look.
Welp, that sucks. I guess the door card has to come off.
Neighbors cat came over to investigate.
Repaired wiring.
I got the heatercore out and it was a mouse hotel, as per usual. Surprisingly, like the rear fan, the front van squeaked for a second and then worked fine. I will do my best to lube the bearings.
Started cleaning the dash. You can see where the right side of the nose was bodyworked by the black paint they used on the inside. Looks like they drilled a lot of holes to pull it back to flat-ish and then bondo'd it smooth.
During the removal of the heatercore I forgot about this screw and I didn't even feel it break. Oh well. I'll make a bracket. It's hidden behind the vent tube and brake reservoir line, don't forget it!
Next up, more cleaning. I am not sure how to clean the fuse box without unpinning every single wire. Compressed air maybe.
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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jlrftype7
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Joined: July 24, 2018
Posts: 4549
Location: Chicago
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| Posted: Tue Nov 12, 2024 11:57 am Post subject: Re: In for a penny, in for a pound |
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Loved the helpful/curious cat that probably smelled Rodent when it got that close to the interior... 
"there's LUNCH somewhere in this Van if I keep looking"...
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'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
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do.dah
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Joined: August 27, 2015
Posts: 797
Location: Washington
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| Posted: Tue Nov 12, 2024 11:57 am Post subject: Re: In for a penny, in for a pound |
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| How do you get your solder seal wire splices to look so nice?!? |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Tue Nov 12, 2024 9:32 pm Post subject: Re: In for a penny, in for a pound |
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| do.dah wrote: |
| How do you get your solder seal wire splices to look so nice?!? |
https://www.ebay.com/itm/334423949597?_skw=solder+...3431813184
They are specific wire connectors. Not only do they heat shrink, they have low temp solder in them that provides a solid connection. Would I use them on an airplane motor? No. Do I use them on just about everything else? Yes. Just mesh the two wire end strands into each other/next to each other and heat the whole thing with a small torch. I like to do the outsides first so it holds the wires in place solidly and then I can move my fingers around without burning myself. With a small bit of effort I can also pull them apart, which is a benefit to me because sometimes I mesh the wrong two wires.
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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do.dah
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Joined: August 27, 2015
Posts: 797
Location: Washington
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| Posted: Tue Nov 12, 2024 10:21 pm Post subject: Re: In for a penny, in for a pound |
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| 4Gears4Tires wrote: |
| do.dah wrote: |
| How do you get your solder seal wire splices to look so nice?!? |
https://www.ebay.com/itm/334423949597?_skw=solder+...3431813184
They are specific wire connectors. Not only do they heat shrink, they have low temp solder in them that provides a solid connection. Would I use them on an airplane motor? No. Do I use them on just about everything else? Yes. Just mesh the two wire end strands into each other/next to each other and heat the whole thing with a small torch. I like to do the outsides first so it holds the wires in place solidly and then I can move my fingers around without burning myself. With a small bit of effort I can also pull them apart, which is a benefit to me because sometimes I mesh the wrong two wires. |
Oh, I know that, and I have been using them for decades. I've used mini electric heat guns, special butane heat pens,, mine do not come out anywhere near as nice as yours. |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4180
Location: MD
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| Posted: Wed Nov 13, 2024 7:05 am Post subject: Re: In for a penny, in for a pound |
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Hahaha, well I have nothing for you there. No special technique I can think of. I use a Bernzomatic butane soldering torch with the tip removed for heat shrinking. It's a bit annoying refilling it, but it's worked the best out of all the methods I've tried so I deal with the refills.
https://www.homedepot.com/p/Bernzomatic-Detail-Cor.../304813553
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition
Last edited by 4Gears4Tires on Wed Nov 13, 2024 8:56 am; edited 1 time in total |
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