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What did YOU do to your van today?
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bobbyblack
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PostPosted: Fri Sep 08, 2017 12:15 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Flossie the mobile tool chest (left) helped out on the mission to eval and RnR Cosmo's flickering charge light condition. Turned out the DoubleCheese (our derelict '86 parts van) had the Alt needed to get Cosmo (right) all ready for the weekend camp out! After Alt was replaced, light was off on dash, and volts out of Alt to ground showed 14.4. I'd call it a lunchhour success!! My daughter Mags was instrumental in the swap, and we really made a great team! Hope the rest of the trip is uneventful Smile

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Paulbeard
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PostPosted: Sun Sep 10, 2017 2:52 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Installed the 3D Odometer fix.
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Bman
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PostPosted: Sun Sep 10, 2017 6:55 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Have my dash out on an 84 Doka, today's job was to get all of those connections clean:

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jokeraus
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PostPosted: Mon Sep 11, 2017 9:58 am    Post subject: Re: What did YOU do to your van today? Reply with quote

Finished installing an in-floor storage container I built, very tight fit between the frame rails. Max storage space achieved.
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Re-mounted the fuel pump and plumbing for an espar D2 cabin heater. I was using a 1 gallon lawnmower tank mounted where the floor storage box now is. This was a temporary solution. Now it will be pulling from a 5 gallon wavian style jerry can mounted on the rear storage box. This will be much easier to fill and run it for a longer period. Hopefully the fuel pump clicking will not be overly annoying. We'll see
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bobbyblack
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PostPosted: Mon Sep 11, 2017 6:48 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Played a little game of "how many fingers is Flossie holding behind her back?" as I had been observing a drip on the passenger side push rod tube cover.

I had guessed one, maybe two... wrong! THREE!!!

Contemplating options.

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T3 Pilot
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PostPosted: Mon Sep 11, 2017 7:47 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Replace them with these.......

http://www2.cip1.com/ProductDetails.asp?ProductCode=C13%2D4109
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bobbyblack
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PostPosted: Mon Sep 11, 2017 7:53 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

T3 Pilot wrote:
Replace them with these.......

http://www2.cip1.com/ProductDetails.asp?ProductCode=C13%2D4109


Those look real sweet! Thanks for the hint!
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danfromsyr
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PostPosted: Tue Sep 12, 2017 5:48 am    Post subject: Re: What did YOU do to your van today? Reply with quote

Bobby, those are all installed backwards. the tubes have a slight slope towards the block.. so oil drains.
in that orientation the oil sits against the O-ring seals and well. over time it's going to get by some..

remove them, replace the O-rings and put the larger tube toward the block..

but yeah I like the spring loaded ones better..
bobbyblack wrote:
Played a little game of "how many fingers is Flossie holding behind her back?" as I had been observing a drip on the passenger side push rod tube cover.

I had guessed one, maybe two... wrong! THREE!!!

Contemplating options.

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bobbyblack
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PostPosted: Tue Sep 12, 2017 6:48 am    Post subject: Re: What did YOU do to your van today? Reply with quote

danfromsyr wrote:
Bobby, those are all installed backwards. the tubes have a slight slope towards the block.. so oil drains.
in that orientation the oil sits against the O-ring seals and well. over time it's going to get by some..

remove them, replace the O-rings and put the larger tube toward the block..


Well, crap! Dan, are you sure? When I was doing that job, I had a guess at perhaps this would come true some day, however I had several clues:

1: the ends of the tubes are different sizes. The seals for each end is different. I had several dozen to play with, as the PO had done this a couple of times, minimum... I was just following suit on what he had in place, really.

2: Following #1, there are actually 2 different styles of tubes in this mix. Obviously I tried to stay with each type within it's group when doing the remove/clean/install on the head reseal, but it has become entirely obvious that I should have ordered the OEM one piece tubes. And, no I am not going through the re-seal again just to put one-piece tubes in, even if that is the "right way" to solve this.

3: These are spring loaded units, they have double o-ring seals, and in fact I went through them all and replaced the o-rings. On another note: these things are extremely sharp. Also, I was clued in by #1, AND the part where installing these the other way proved impossible, as gripping them adequately to shove them into place for expansion via spring after snapping into the holes was quite difficult, there would be no way I could get enough clamping force on the small end to achieve installation in the opposite direction.

I guess it is possible I was using my hands to do these ops, and instead there is a tool. That could explain it. I still can't get past the part where the size of the end/rubber seal are end-for-end different, just like the one piece OEMs.

I am guessing that the issue we are experiencing is that these replacements were offered in the way-back, and did not conform to the well-thought-out, properly designed units that are on the market today. I'd have a guess at a flash-in-the-pan outfit that the PO got a couple sets from in the early '90s which did not heed the engineering principals mentioned above. (maybe JC-Whitney?)

Its also possible that I have mixed all of the info above up with a variety of other engines I have worked on, but I am pretty sure I remember this rebuild fairly well. I also guess it is true that i didn't Mic the ends to be entirely sure they were indeed different. It seemed sort of obvious just by eye, and slipping the replacement end-rubbers on. Which, really, means nothing.

I can give it another try going the other direction. I'm game. I have to pull the rockers, etc anyway, and pull these pesky ones out. Its funny tho, 5 of 8 are clean and dry.
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BCE56
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PostPosted: Fri Sep 15, 2017 6:31 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Got the Syncro back from the shop in preparation for my summer road trip.
Replaced the heater hoses (way overdue) and bypassed the rear heater. Repaired a couple of minor leaks, drained and replaced the coolant, bled, pressure tested and drive tested for leaks- so far so good. Upon inspection the plastic pipes appear in good condition so expensive replacement is postponed for now. Replaced the radiator deflector baffles.
Checked CVJ bolts and boots, tightened exh. bolts and others. Changed oil and filter and lubed shift linkage.
It's about ready to hit the road, purring like a kitten.

Then the clock died. I'll look into this when I have the instrument panel apart to install LED bulbs.

Ordered GW A/C reinforcement brackets. The rear cover has some alarming cracks. The tubes are kinda shaky too...

..............

UPDATE 9/21:
Installed the A/C brackets. Just in the nick of time! One side had failed completely since I placed the order. 20 bucks well spent.

After some local driving, overflow tank needed only about a pint of coolant- I think system is bled adequately.

Round two on the taillights: (Previous effort was a bust.) Ordered a 4-pack of internet LED running lights, these with 360' as well as rear-facing elements. Maybe brake lights next.

Haven't pulled the dash yet. I hope the dead clock is just a connection problem, otherwise it will get a stick-on.

Summer road trip has been postponed due to scheduling issues w/ my contacts in CO. Looks like it will be an Autumn road trip this year, weather permitting.
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bobbyblack
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PostPosted: Sat Sep 16, 2017 6:46 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Finished my skylight screen/Velcro replacement project.

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djkeev
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PostPosted: Sun Sep 17, 2017 12:31 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Installed an in-line fuse to protect my fuel pump and digifant injection system from burning up as discussed in this thread......

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

Then I took the Van to see some of its friends and ancestors at the All Air Cooled Event in Flanders NJ.

Dave
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singletrackrod
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PostPosted: Tue Sep 26, 2017 1:47 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

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After
New Powerflex bushings at outer RR, steering rack, lower sway bar linkage and lower control arms. New control arm boots, ball joints, hubs and a Big Brake kit.

Looking forward to getting her aligned and then finding a curvy canyon road.
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campism
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PostPosted: Tue Sep 26, 2017 3:51 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

singletrackrod wrote:
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Barum tires on a Vanagon? Last time I saw Barums they were bicycle tubulars about 30 years ago.
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singletrackrod
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PostPosted: Wed Sep 27, 2017 7:47 am    Post subject: Re: What did YOU do to your van today? Reply with quote

Yeah, I couldn't find any Clement's or Vittoria's. This is my second set of Barums. They seem to wear pretty wear and carry an XL load rating.
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PostPosted: Wed Sep 27, 2017 8:23 am    Post subject: Re: What did YOU do to your van today? Reply with quote

If you have not already done so, you might want to add some details (size you use, load rating, price, vendor link, etc.--and PIX, don't forget the PIX) about these tires to the existing tire sticky. It always helps to have more information about suitable tires for our beloved vehicles. Thanks!

https://www.thesamba.com/vw/forum/viewtopic.php?t=584507
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PostPosted: Wed Sep 27, 2017 9:17 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Drove my van as the Odometer rolled past 367000 miles. I may have done a few things to it along the way but I can't remember them all.

Stacy
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PostPosted: Thu Sep 28, 2017 12:56 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Converted from the old square style fuel filter to the newer cylindrical style. Used a 1/2 to 3/4" PEX fitting to bridge the different sized hoses. Hoping the cavitation noise goes away.
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PostPosted: Thu Sep 28, 2017 8:39 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

2 1/2 days of sanding the front end, having the two holes in the windshield frame patched/welded and the front end painted. Installed a new windshield and seal today, after watching GoWesty's video on how to do this. Found it was better for me to start pulling the rope from the bottom instead of from the top as in the video. Put the big tube bumper, lower front grille, antenna and wiper shafts on. Installed Porsche dual nozzle windshield washers and new hoses. Another day or so should have everything back on and ready for a trip to Utah next week.
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BCE56
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PostPosted: Sat Sep 30, 2017 6:28 pm    Post subject: Re: What did YOU do to your van today? Reply with quote

Yesterday I began replacing running light bulbs with LEDs. As both sockets are powered, I had bought a 4-pack. These are marked 8W. I was unable to remove the inboard bulbs (sockets marked 32 CP) so only installed the outboard (8 CP) ones. Tested before reassembly and found neither bulb in the righthand housing worked. Odd, they worked before...
I monkeyed around with it for a while with no success, and retreated flummoxed.
Mixed myself a toddy or two to enhance cogitation as I considered how to proceed. A quick look at schematics reminded me there are two 10 amp fuses for running lights- left and right, front and rear are fused separately.
Finished the last of my toddy and went out for further testing.
Hit the dash switch and sure enough the right front marker did not light.
So. Check the fuse, dummy.
Yep, #7 was fried. Stuck in another fuse which also fried instantly.
Now what? I know there's a short, but where?
Today I tackled it again. I removed the harness from the lamp housing, and replaced the fuse. Aha! Now the front marker worked so I know the short is in the lamp housing. I could see nothing wrong with the outboard socket, no damage or corrosion anywhere.
I had to destroy the inboard bulb to remove it. Inside, rather than a spring contact like all the other sockets, there was just a loose wire with a small brass button terminal. This had apparently shifted, shorting the bulb, and wedging the base.
Success!
I checked the LH housing and found the same type of terminal. These seem to be factory installed rather than jury-rigged. There is some doubt as to whether the inboard lamps are operational on Vanagons delivered to the US. FWIW, my lamp housings are stamped "USA".
Live and learn...

On to the next fiasco!
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