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Baywindow to Beijing resto thread
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MadMax78
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PostPosted: Mon Jul 09, 2007 3:56 pm    Post subject: Baywindow to Beijing resto thread Reply with quote

Hello everyone,

As some of you might have already read here on the forums 40 adventurers including myself will depart for a journey of a lifetime. I will be driving my 1978 T2b ASI Riviera. In a large convoy we will travel from Amsterdam to Beijing, China to support the Dutch athletes at the 2008 Summer Olympics. An orange DAF city bus will lead the convoy formed by over twenty other orange colored cars and motorcycles across the 17500 kilometers and 14 countries that separate us from our destination and the Dutch Olympic Team. Meanwhile we hope to find significant financial support for the Right to Play foundation!

You can find more information on our project on www.amsterdambeijing.com

So that's a little of the background story. Now back to the bus. We bought our bus about a month ago and it's in a pretty good condition. There is hardly any rust on the body and the interior still looks pretty mint. The car has 31k miles on it so the engine should be in decent shape too.

Of course a lot of work has to be done to get the bus ready to leave Amsterdam in June 2008. As you can imagine a lot of things need to be adressed for this bus to survive this 10.000 mile ordeal. We'll be needing lots of parts to get our camper in shape to participate in this event. If you are interested in helping us or you know someone here in Europe who can help us, you can always contact us at [email protected]. We'll be updating this first post in this topic every now and then with a updated preparation list.

Preparation list
Installed new radio with 2 speakers in the doors, 2 tweeters on the dash and 2 4-way speakers in the back
Aux wiring added from front to back
Installed headlight rock guards
Replaced engine seal (which was mostly gone)
Hooked the thermostat back up
Replaced camper interior light above sink
Installed VDO tach, oil pressure, oil temp and voltmeter with switch to check both batteries
Installed Dakota Digital CHT
Installed window washer pump
Added aux fuseboxes up front and in camper area
Installed Waeco SinePower sinus Inverter 300W
Installed 2 outlets for city power and 2 for the inverter (230V)
Installed 2 12V outlets
Installed water tank level meter
Replaced old water tank fill, city water inlet and sink outlet with new parts.
Refurbished power inlet, took it out, resprayed looks mint again.
Placed a 230V fusebox with circuit breaker
Replaced all water lines and pump, installed water filter and new faucet.
Replaced old fridge with new Waeco CR65 fridge
Installed battery Waeco perfectcharge, dual battery charger, charges camper and engine battery when hooked up to city power.
Installed Fresh air fans
Built custom bull bar with spare tire
Built custom swing away spare tire carrier (as seen on landmark campers)
Installed central locking on front doors
Converted front reflectors to indicators
Replaced rear side markers
Replaced rear lamp units
Repaired interior lights and interior light switches on door pillars
Spray painted outside of the bus because old paint was cracking due to sun/age.
Replaced washer fluid nozzles
Installed heavy duty sway bar up front
Powdercoated the rims high gloss black
New tires have been ordered, Vredestijn Comtrac
New Koni shocks are waiting to be installed
Installed engine lid lock
Replaced fuel lines
Repaired stock buzzer
Installed buzzer to alert you when you leave your lights on
Installed 3rd brake light
Replaced air and oil filter
Installed new kickpanels
Replaced broken heating booster fan
Installed new hoses from booster fan to heater box, these were missing.
Replaced all 4 CV's
Replaced rear brake shoes
Replaced rear brake cylinders
Replaced rear wheel bearings
Replaced all 4 shocks with Koni's
Raised rear to correct sag

Also check out our shakedown video on our team page: www.baywindowtobeijing.com Smile

Image may have been reduced in size. Click image to view fullscreen.

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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
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Last edited by MadMax78 on Mon Apr 20, 2009 2:01 am; edited 17 times in total
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Quadratrückseite
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PostPosted: Mon Jul 09, 2007 4:30 pm    Post subject: Reply with quote

New fuel lines too, I hope? Laughing
Great website!
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Duncwarw
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PostPosted: Mon Jul 09, 2007 5:56 pm    Post subject: Reply with quote

Great videos. I especially like the 2CV.

Have a great trip, I look forward to more video and/or pics.
The Silk Road should put you in Wuwei at some point. I'd love to see that.

Best of luck with the trip and the competition!

That reminds me, I know a guy in Den Haag somewhere....
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MadMax78
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PostPosted: Thu Jul 12, 2007 6:05 pm    Post subject: Reply with quote

Progress report! Working on all the camper gear and aux gauges.


Took the frigde out to acces water lines and pump:
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Removed water tank
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Installed water tank level indicator and 2 outlets for direct AC
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Installed water tank level sender and cleaned the tank with fresh water tank cleaner.
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Replaced stock american outlets with new european 230V outlets
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Got a Waeco (pronounce WayCool Razz) pure sine inverter wired to the above outlets. Still need to finish/tidy up the wiring
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Removed all outlets for refurbishing
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Installed tach
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More gauges Cool
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New wiring in the front, still a lot to do here.
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Mounted a pod for the CHT, didn't want it on top of the dash and this looks pretty neat.
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That's all for now, gonna finish up the camper stuff CHT and dual battery and next week the bus is planned for a respray. Very Happy
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
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Rocknrod
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PostPosted: Thu Jul 12, 2007 6:21 pm    Post subject: Reply with quote

That wiring is beautiful!

Have fun on your trip
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Duncwarw
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PostPosted: Thu Jul 12, 2007 7:06 pm    Post subject: Reply with quote

Yes, nicely done so far.

Look out for corrosion. Heat shrink and dialectric grease along with solder will go a long way to help prevent future surprises.

Neat work.
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MadMax78
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PostPosted: Fri Jul 13, 2007 1:50 pm    Post subject: Reply with quote

I put some grease on all the holes i drill in the body. So that should be allright, thanks for the tip though.

Got the new water system installed today and received some stuff from Bus Depot so lot's to do again!
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
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Duncwarw
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PostPosted: Fri Jul 13, 2007 2:58 pm    Post subject: Reply with quote

Oh, I meant the electrical connections themselves.

Keep up the good work, I'm enjoying your progress.
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PostPosted: Sun Jul 15, 2007 9:08 am    Post subject: Reply with quote

Last night we finished up the wiring for the new gauges and they are all working great. Also the pertronix ignition has been installed. This morning we took it out for a test run and everything still works fine. We finally got the time to check out our rivi awning for the first time.

Pertronix installed
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Awning
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Seriously vintage
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Our bus is in a good state rust-wise and we like to keep it that way. However the sun has really cooked the paint and it has cracked and looks shit. So we decided it needs protection and has to be sprayed. We're off to sanding the bus tomorrow and the days to come. When that's done we'll get some new layers of L20B shining on the car again.

We took everything of the car and closed all the holes to prevent dust coming in the car (or at least as little as possible)

Of course we had to have the VeeDub logo Cool
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The spare tire mount has cracked the body a little. We probably aren't going to put it back, still looking for that roobar.
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Removed mounting bolts from taillights just ducktape holding them in place to drive it to the spray painter tomorrow.
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Outlets removed and holes covered
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I'll post some pictures when the bus is shining again Very Happy
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
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atmellovw
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PostPosted: Sun Jul 15, 2007 9:17 am    Post subject: Reply with quote

The pickup on my Pertronix worked itself loose after 100 miles. I know this has happened to others here as well. I put a small amount Permatex sealant on the threads to keep it from happening again. Do a search and you can learn how others dealt with the issue.
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PostPosted: Sun Jul 15, 2007 10:08 am    Post subject: Reply with quote

I'll have to check mine. It's been in there for more than a year and 30K miles and as far as I know it's never moved.

I'll let you know.

I know it's probably considered sacrelige by some, but I not only left my spare on the front but I removed the well in the back too. MUCH nicer with a flat floor and I have a good-sized access hatch to my aux batt and relays.
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MadMax78
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PostPosted: Tue Jul 17, 2007 4:15 am    Post subject: Reply with quote

Thanks for the heads up on the pertronix, will take a look.

I finished sanding the bus today. Should roll out with new paint on friday.

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Vee-Dub Cool
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
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PostPosted: Wed Jul 18, 2007 6:58 am    Post subject: Re: Baywindow to Beijing (pic update 07-17) Reply with quote

MadMax78 wrote:
Preparation list
Installed new radio
Fixed side marker lights
Auxilary wiring added from front to back
Installed headlight rock guards
Replaced engine seal (which was mostly gone)
Hooked the thermostat back up
Replaced camper interior light above sink

In progress
Installing VDO oil temp, oil pressure, tach and voltmeter gauges and DD CHT gauge.
Installing a pump on window washer bottle
Refurbishing the fresh water system
Converting the 125V system to 230V
Adding auxilary fuseboxes (6 fuse) in front and camper area

Installed tach

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More gauges

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I can see what looks like an ammeter rather than a voltmeter. Does the ammeter have an internal or external shunt resistor?

Why have you fitted a VDO Cockpit, 0~10 Bar oil-pressure gauge, rather than a 0~5 Bar oil-pressure gauge, which has a more appropriate pressure range, for the VW air-cooled engines?

A few years ago, I obtained from an auto jumble sale, a second-hand, 80 mm VDO Cockpit tachometer, of a similar appearance to the one you have fitted, but have yet to get mine working.

Noting that you are upgrading the electrical system, by retro-fitting accessory fuse boxes and relays, yo might with to consider the use of the one ore more of the following item:

Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=327973

This six-position, relay mounting cum connector block (dimensions 110 mm x 75 mm x 25 mm), made by Rists (a division of Lucas Industries), is one of several, I salvaged from various Austin Montego & Rover Montego cars. They were also fitted to the earlier Austin Princess. This item accepts accessory relays, buzzers and flasher units, having upto five ¼ inch (i.e. 6·3 mm) male-blade connector terminals.

I have used two such items, suspended unobtrusively, beneath the steering-column support bracket, of my British specification, 1973 VW Type 2, to make provision for, an additional twelve accessory relays.

Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=327969

Noting that your 1978 VW 2000 Type 2 Rivierra campervan, is of USA or Canadian specification, you might wish to check whether it is still equipped with USA or Canadian specification headlamp dimmer relay, which does not incorporate the headlamp flasher facility, which British & European owners, take for granted.

Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=327513

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http://www.thesamba.com/vw/forum/album_page.php?pic_id=328148

The five-terminal configuration of the British & European specification, headlamp dip & flasher relay for the VW-Audi (VW part No. 411 941 883B), labelled 30, 56, 56a, 56b and S; terminal 30 being in the same position as the locating lug (not an electrical blade-terminal) of the North American specification headlamp dimmer relay.

The Swedish specification, 1974~79 VW Type 2s, had electrically pumped windscreen & headlamp washers as standard. Note the extra large, black plastic, windscreen-washer reservoir, whic replaces the right-hand kick board.

Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=328679

That's all for the moment.

Regards.

Nigel A. Skeet
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MadMax78
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PostPosted: Wed Jul 18, 2007 11:15 am    Post subject: Reply with quote

Thanks for all the info Nigel, greatly appreciated.

About those gauges, I got them at a VW event and the gauges were limited. They were pretty cheap though so I thought I'd just settle with a 10 bar scale, not that bad at all really.
The other gauge in the image is indeed an ammeter, however since installing it appeared to be quite a hassle I'll swap it for a voltmeter. All the wiring is already in place, just need to get the voltmeter. I only used the ammeter to test the alignment of the holes I cut in the dash.

The headlamp washer are kickass. Never knew they existed, I'll keep my eyes open on the lookout for em. Cool
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
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PostPosted: Sun Jul 22, 2007 5:48 am    Post subject: Baywindow to Beijing Reply with quote

For those camping in their 1968~79 VW Type 2 campervan, in colder regions of the World, such as the deserts and high mountain ranges, which one will encounter, on the overland route from Amsterdam to Beijing, there is a very tidy heater installation as follows, about which I first learned several years ago, in some literature sent to me by QB Autocamp, a British mail-order company, specialising in VW Type 2 parts.

Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=343618

This Riviera BVW-2 brand, floor-recessed, LPG-fired, warm-air heating system, was specifically designed for modest-sized campervan, such as the 1968~79 VW Type 2, as illustrated above.

The main advantage to this type of heater, is that it does not take up any space in the main passenger cabin or any of the storage lockers, which is the case, with the various types of blown-air heating system.


Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=343620

This Riviera De Luxe brand, floor-recessed, LPG-fired, warm-air heating system, was specifically designed for trailer-caravans and trailer-tents, as illustrated above, but can also be used in larger campervans.


Image may have been reduced in size. Click image to view fullscreen.


http://www.thesamba.com/vw/forum/album_page.php?pic_id=368611

This is an in-situ picture, of a Riviera, floor-recessed, LPG-fired, space heater, which can be installed in either trailer caravans or campervans, such as the 1968~79 VW type 2, for which there is/was a special version, designated version BVW-2, as illustrated earlier.

More details of the installation, are illustrated in the following book:

John Wickersham, "The Caravan Manual", Chapter 11 – Installing Space Heaters & Water Heaters, pp127~129, Haynes Publishing Group, 2nd Edition, 1996, ISBN 1 85960 308 4

Regards.

Nigel A. Skeet
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MadMax78
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PostPosted: Sun Jul 22, 2007 7:12 am    Post subject: Reply with quote

That looks like a cool option, however it is ruled out for us. We won't be carrying any gas bottles because they are large and heavy and can't be filled everywhere we will be going.

We'll be cooking on a Coleman unleaded gasoline stove and we got a very energy efficient fridge (Waeco CR65) which only draws 1.9 Ah at 32 C / 90 F.

We haven't really been thinking about whether or not we'll be fitting the bus with some sort of auxiliary heating device like the BA6. We still need to get the stock heater back up and running and then we'll see whats what.
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
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MadMax78
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PostPosted: Sun Oct 14, 2007 10:22 am    Post subject: Reply with quote

Long time no update, but a lot has happened, see for yourself!


All water lines replaced, aslo installed this new water pump.
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Installed this light buzzer, buzzes when lights are left on and the door opened.
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Installed 300W Waeco Sinus inverter and a Waeco Perfectcharge dual battery charger under the Z-bed.
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New fridge, runs on 12V. This fridge is extremely efficient, only draws 1,4 Ah at 25 degrees Celcius outside temperature. We'll fit a air vent in the gap which was left above the fridge by the old one.
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Fixed the interior lights, they we're all broken and replaced the old light above the sink with a new one.
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Installed fresh air fans, bought from thesamba
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I bought a central locking kit a few months ago but never really got the guts to try installing it. Anyway, I did install it and it works! Was quite a lot of work to put a new cable into the door, had to take it out to drill a hole.
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Picture of the actuator
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Control unit installed behind the right kickpanel
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Installed a heavy front sway bar up front. This one is from Empi and I really like it, makes a huge difference, I'd recommend this upgrade to anyone. Easy to install too, only took me an hour or so.
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New Koni shocks are in, waiting to be installed. Still waiting for the rear ones.
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Installed 3rd brake light from Hella
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After spray paint we replaced the side markers with new ones because the old plastic became brittle and started falling apart. We decided to change the front reflectors to indicators and change the rear ones to orange side markers. Here's a picture of the inside of the front door with the new indicator installed.
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Picture of the new lenses.
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Sandblasted the rims and powdercoated them in high gloss black. Touched up the old tires to look good again. New Vredestein Comtrac's have been ordered, will get those on soon.
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New city water inlet and new sink drain outlet.
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New water tank filler, special thanks to Mintonman for getting me this one!
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Installed 230V outlets, water tank level indicator, battery charger control panel and 12V outlets. (sorry for the fuzzy picture)
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All wired up
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New 12V fusebox and 230V fusebox with circuit breaker which immediately cuts off power when it detects a short, so the risk of electrocution is virtually non-existant.
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New water filter installed.
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Connected the water tank back up, you can see the water level sender in this picture.
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We had a custom roo bar made which is a bit closer to the body than the stock model. Also we had a rear spare tire carrier made so we can carry a total of two spares. These are a few pictures from a recent charity event. In the pictures you can see a few other cars which will be participating in the Amsterdam Beijing rally aswell.
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That's about it for now. Let me know what you think, comments and suggestions are always appreciated!
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
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Last edited by MadMax78 on Sun Oct 14, 2007 3:00 pm; edited 2 times in total
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IFBwax
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Joined: April 05, 2005
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Location: Beaverton, Oregon
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PostPosted: Sun Oct 14, 2007 10:37 am    Post subject: Reply with quote

Great job.. what a feat! I'd love to do something like that, but I'm sure it would mean a divorce and child custody case and of course my boss would fire me... but aside from all of that.. maybe if I win the lotto!!!

But really nice job. Let's see some engine shots!
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Owner of: "The Party Pickle" (a 1979 2 Liter FI "Raby Camper Special" Sage Green Westy Campmobile) & "Charlie Brown" (a 1979 2 Liter FI "Rob Grant Rebuild" Agate Brown/Dakota Beige Station Wagon)


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Bay74
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Joined: August 18, 2006
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PostPosted: Sun Oct 14, 2007 10:45 am    Post subject: Reply with quote

It's looking great! I hope i can get around to half the upgrades you have done.
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MadMax78
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PostPosted: Mon Oct 15, 2007 2:32 am    Post subject: Reply with quote

Thanks for the positive feedback!

About those engine shots... they are not all that amazing Very Happy

We haven't put a lot of time in the engine/brakes/transmission yet. We're just gonna take a few week break of working on the bus and after that we'll drop the engine, clean out the engine bay, clean the fueltank, fix the sender etc. etc.

We only did some urgent things to the engine, replaced the engine seal, replaced the fuel lines, installed aux heater blower hoses which were M.I.A., replaced coil with a blue coil, installed pertronix ignition and we got wiring in for the aux battery and for the new gauges (oil temp & pressure sender)

Here's a picture of our engine when we got the bus a few months back. Pretty much your typical cali engine I'd say.

Image may have been reduced in size. Click image to view fullscreen.

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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt Injection & Ignition // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply , Busted Bus, Aircooled Technology & DIYAutoTune
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 27.000km
http://www.oranjetrophy.nl
******************************************
Camper Special Club Member
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