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Iron Lion to Capetown
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MadMax78
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PostPosted: Sat Aug 01, 2009 7:16 am    Post subject: Iron Lion to Capetown Reply with quote

Hi guys,

So we thought it would be time for another little endurance test for the T2. As some of you might recall we already did a little warm-up last summer when we drove 10.000 miles from Amsterdam to the Beijing Olympics. You can read more about that trip here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=241979

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


Anyway, next summer things will get serious and we'll be driving our T2 (named Iron Lion for the occasion) from Amsterdam to the soccer world cup in Capetown (South-Africa). It's a 12.500 mile trip through the harshest of conditions. Sand, mud, high temperatures, heavy rain, lions(?). The route will lead us through 15 countries of which 11 are in Africa and 4 in Europe.

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Last year we put some major tool time into our bus. We built a Camper Special engine, rebuilt the suspension, overhauled the camper electrics, fresh paintjob and countless other jobs.

Of course there is still room for improvement and we've planned a couple of things already. One of them includes installing an external oil cooler and installing a MegaSquirt fuel injection system parallel to the stock L-jet.

This time round there will be at least 3 participating VW's, a 75 bug, a stock 72 bus and our ride.

Anyway, we'll keep you posted in this topic on our prep work, and of course when we'll be hitting the road by April 2010.
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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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Opossum
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PostPosted: Sat Aug 01, 2009 8:26 am    Post subject: Reply with quote

WOW !!! That is a great trip ! I can't wait to follow your thread.
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Cpav
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PostPosted: Sat Aug 01, 2009 8:30 am    Post subject: Reply with quote

Keep your eye out for Dr. Livingston.

I heard he was in a VW too.

Maybe he's just in the south of Egypt waiting for a fuel pump to be delivered.
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mikefenton
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PostPosted: Sat Aug 01, 2009 8:38 am    Post subject: Reply with quote

if you looking for things to do with Livingstone, then about 40km out side of Gaborone (botswana) theres the livingstone memorial, one of his familys graves are there.
http://www.botswanatourism.co.bw/attractions/livingstone_memorial_kolobeng.html
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MadMax78
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PostPosted: Sun Aug 02, 2009 10:42 am    Post subject: Reply with quote

Thanks for the replies guys Smile

Well, here's the first update, I finished assembling my MegaSquirt II ecu yesterday. It really is an awesome piece of kit, can't wait to get it installed in the bus.

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V3 PCB

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Fully assembled after many hours of soldering.

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I also got a LC-1 gauge and sensor kit to go along with it. With it I'll be able to run the MS in closed loop mode. Besides that obvious advantage I'll also be able to use it to get the L-jet properly tuned.

I'm planning to run the MegaSquirt parallel to the L-jet, so if the MS would fail I can just pull the L-jet plug from the adapter box and plug it back into the L-jet computer and off we go. I drew a wiring harness to illustrate this. I'll be using the original TS 1 in the AFM as the intake manifold temperature sensor and the TS 2 as the coolant temperature sensor. The MS won't have control of the AAR and FP, that will still be taken care of by the double relay. 3 sensors are added on a small additional harness to provide the MS with extra input, these are a throttle position sensor, the LC-1 lamda sensor and a VR-sensor.

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

_________________
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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cool karmann collected
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PostPosted: Sun Aug 02, 2009 1:10 pm    Post subject: Reply with quote

Hats off to you on your trip plans! Although I must say, whoever's driving the bug all that way has got some serious stones...
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peaceful warrior
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PostPosted: Sun Aug 02, 2009 3:37 pm    Post subject: Reply with quote

Man, this is a cool trip........kudos to you for your planning and preparation.
What are your plans/ideas for breakdowns on the way?

I am planning a trip from New Mexico, USA to Costa Rica, Central America next year in a 68 Westy that I am going completely through.

Can't wait to read about your exploits thru the desert and heat!

Best of luck to you! Wink Very Happy
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MadMax78
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PostPosted: Sun Aug 02, 2009 6:44 pm    Post subject: Reply with quote

peaceful warrior wrote:

What are your plans/ideas for breakdowns on the way?


Well, you can't be prepared for anything of course, but good preparation at least minimizes the risk of a breakdown. On our 10k miles to Beijing we had two FI components fail, the AFM and the double relay, but we carried spares so it was just plug and play. Also we had a rear wheel bearing go bad, but we did make it to Beijing on that bearing. We actually replaced it before we left but we didn't install it with the required finesse...

Basically we just carry spares for stuff we think is likely to break or wears, so that meant all FI components, shocks, V-belts, air filters, oil filter, spark plugs, dizzy, track rod, hoses, hose clamps, fuses, alternator, drive shaft, CV's, grease, coil, etc. and a full toolkit of course.
The Mesgasquirt injection system will make it very easy to troubleshoot the engine and make adjustments on the fly if necessary and in case the system fails we can just plug the L-jet back in.

Lot's of stuff can be fixed on the road, but of course you could strike some bad luck and break something that can't be fixed. We'll also be installing sump and transmission guards to prevent such a case Razz .
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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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aircedar
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PostPosted: Sun Aug 02, 2009 8:31 pm    Post subject: Reply with quote

Is there a compelling reason you will be using a throttle position sensor instead of a manifold pressure sensor?
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MadMax78
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PostPosted: Mon Aug 03, 2009 4:30 am    Post subject: Reply with quote

Actually, it uses both, the MAP (manifold absolute pressure) sensor is integrated in the ECU (there is a connection for it on the front of the case, you can't see it in the pics), so I only have to connect a vacuum line to it, that's why it's not in the wiring diagram. The map sensor is the main load sensor, the AFM will only have the function of switchting current to the fuel pump and measuring intake air temp.
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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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Wild Bill
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PostPosted: Mon Aug 03, 2009 1:40 pm    Post subject: Reply with quote

What kind of Gas Mileage are you expecting ?Speaking of gas ... your budget must be fairly high in the petrol purchasing dept..... Shocked

On your Italian leg. I know you will take the ferry across the Straights of Messina but where will you depart Sicily for Africa? Another Ferry?
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kamara
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PostPosted: Fri Oct 23, 2009 10:00 pm    Post subject: Reply with quote

That will be an awesome trip! I grew up in Senegal and will be travelling with you in spirit. My buddy lives in S.A. and has invited me to fly over for the World Cup. Maybe I'll see you there!
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josh
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PostPosted: Fri Oct 23, 2009 11:40 pm    Post subject: Reply with quote

Quote:
I'm planning to run the MegaSquirt parallel to the L-jet, so if the MS would fail I can just pull the L-jet plug from the adapter box and plug it back into the L-jet computer and off we go. I drew a wiring harness to illustrate this. I'll be using the original TS 1 in the AFM as the intake manifold temperature sensor and the TS 2 as the coolant temperature sensor. The MS won't have control of the AAR and FP, that will still be taken care of by the double relay. 3 sensors are added on a small additional harness to provide the MS with extra input, these are a throttle position sensor, the LC-1 lamda sensor and a VR-sensor.

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


A redundant fuel injection system?
That's awesome!
How are you mounting the trigger wheel?
You've sure got an adventurous spirit. Good luck!
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Stoner A is cylinders #2/4 B is #1/3 The plugged bowl is the throttle, the bong is the manifold
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purplegodzilla
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PostPosted: Sat Oct 24, 2009 5:17 am    Post subject: Reply with quote

Thats impressive man. Just dont' get hijack in Somalia.
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MadMax78
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PostPosted: Sat Oct 24, 2009 5:37 am    Post subject: Reply with quote

josh wrote:

A redundant fuel injection system?
That's awesome!
How are you mounting the trigger wheel?
You've sure got an adventurous spirit. Good luck!


We're mounting it instead of the A/C pulley, like this:

http://www.shoptalkforums.com/viewtopic.php?t=125397

We bought a couple of universal trigger wheels and we'll machine those to fit on the hub. If anyone is interested, let me know, I'll have a couple of them for sale soon.

At the moment we are working on sourcing parts and somewhere around christmas we'll have some full time tool time. By then we'll drop the front axle for a full rebuild and drop the engine for large maintenance and to install the MegaSquirt components.

We've also got a Rancho transmission coming our way equipped with a limited slip diff and 5.14 R/P.

Thanks for all the kind words everyone and we'll keep you all posted.
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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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Bursch
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PostPosted: Sat Oct 24, 2009 2:32 pm    Post subject: Reply with quote

Wild Bill wrote:
What kind of Gas Mileage are you expecting ?Speaking of gas ... your budget must be fairly high in the petrol purchasing dept..... Shocked

On your Italian leg. I know you will take the ferry across the Straights of Messina but where will you depart Sicily for Africa? Another Ferry?
We'll be crossing from Trapani (Sicily) to Tunis. Shortest distance on water, we want to drive to Cape Town you know Wink
There is another ferry trip, 24 hours from Aswan (Egypt) to Wadi Halfa (Sudan) which will be quite a challenge.

Gas mileage is always pretty bad, you're driving around in a bus in full raid equipment, carrying a lot of stuff like spare parts, water, fuel, food, etc

Petrol isn't that expensive in most parts of Africa, but the biggest downside is the amount of fuel you need to carry to be able to cover 600 miles without refueling
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt & EDIS // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply, Busted Bus & Aircooled Technology
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 28.000km
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Bursch
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PostPosted: Sun Nov 08, 2009 4:04 pm    Post subject: Reply with quote

Just a small update. Been working on wiring for the Megasquirt and removing the Amsterdam - Beijing stickering.

Old spare ECU is being converted to connect the Ljet system to the megasquirt.
Madmax78 wrote:
I'm planning to run the MegaSquirt parallel to the L-jet, so if the MS would fail I can just pull the L-jet plug from the adapter box and plug it back into the L-jet computer and off we go.


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


Sure, add a few wires here and there

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The old Amsterdam - Beijing stickers removed. After a proper rinse and wax-on wax-off shines like never before. Orange Trophy Amsterdam - Cape Town outings will be applied next week

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Stickers removed, and then some... Rolling Eyes

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Transmission and sump skid plates as per VAG Ratgeber for 091 transmission and type IV. According to the blueprints supplied by VW in 1984. 4mm steel protection still allowing for airflow.

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

_________________
1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt & EDIS // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply, Busted Bus & Aircooled Technology
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 28.000km
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BUSBOSS
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PostPosted: Sun Nov 08, 2009 4:29 pm    Post subject: Reply with quote

Best wishes on your preparations and journey.

Are you still going to promote Right To Play? I hope so.

http://www.righttoplay.com/site/PageServer?pagename=USA_homepage
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Bleyseng
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PostPosted: Mon Nov 09, 2009 8:52 am    Post subject: Reply with quote

Looking good guys! That tranny skid plate looks way cool...
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Bursch
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PostPosted: Mon Nov 16, 2009 1:00 pm    Post subject: Reply with quote

Another important update!

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Wheelskin steering wheel cover, cross-stitched with approx. 20ft of 1mm waxcord. Took me 5-6 hours as a novice.

Genuine Leather Cool yeaaah
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1978 T2b ASI Riviera Plan I // Camper Special with MegaSquirt & EDIS // 091 with 5.14 R/P and Peloquins LSD
Powered by Just Kampers, German Supply, Busted Bus & Aircooled Technology
2008: Amsterdam - Beijing - Olympics -- 17.500km
2010: Amsterdam - Cape Town - FIFA World Cup -- 26.000km
2014: New York - Rio de Janeiro - FIFA World Cup -- 28.000km
***********************
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