| Author |
Message |
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
 Posted: Mon Feb 05, 2024 5:18 pm Post subject: 1989 Base Model/Blank Slate Build Thread |
 |
|
Despite already having two working Vanagons and, not needing or wanting another project, back in the summer of 2019 I decided to follow-up on a listing in our local craigslist for a vanagon that “had a good body, rebuildable motor, no transmission, no brakes, no radiator or cooling pipes, no gas tank or fuel system, a bare-bones interior, and lots of extra parts!” The ad also said “Need to Sell, Moving out of State.” Out of curiosity, I called and made arrangements to go take a look. The vanagon in question was a 1989 base model that was originally owned by Campbell Nelson Volkswagen here in North Seattle. Apparently, Campbell Nelson had three of these vans that they used as parts runners. They were all bare-bones models with no frills! No headliner and a very stripped out interior. No radio or speakers, no tach and none of the body sound-deadening or insulation that other models had.
Loading on to a trailer.
The extra parts...
More extra parts...
The owner who was advertising on craigslist owned a dry cleaning business and purchased the van to be used as delivery van. He installed a plywood floor and several racks to hang clothes and draperies on for delivery. He also had the company logo and stickers placed on the outside. After 204,000 (+/-) miles sometime in 1997, the van developed issues and was parked in a barn. Over the years, as it sat the owner started stripping parts for one of his other Vanagons. Being a base model, there was not a lot left to strip out! I saw the van and realized that despite a very small amount of surface rust (bad repair) behind the driver’s side rear wheel, the body was in GREAT shape. It would be the perfect blank slate to build out as my I made the owner an offer and he accepted. The following weekend, my sons and I hauled it home on a trailer.
in the ferry line
It sat parked in my driveway for a couple years while I slowly cleaned, prepped and accumulated the parts needed to get it back on the road.
The following is my documentation of the ground-up rebuild that is still in progress. Stay tuned!
Gareth
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
 |
jimf909 
Samba Member
Joined: April 03, 2014
Posts: 7462
Location: WA/ID
|
| Posted: Mon Feb 05, 2024 6:37 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
Neato. The universe seems to collect vanagons in tiny pockets. Kinda like a squirrel with nuts.
Looking forward to the work!
_________________
- Jim
| Abscate wrote: |
Do not get killed, do not kill others.
|
Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Wed Feb 07, 2024 2:38 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
Once I got it home, I started cleaning and building a list of parts that were needed to get it back on the road. The "rebuildable" motor that came with the van looked like it had been sitting outside in the elements for years and was in pretty bad shape. So...Craigslist to the rescue. I acquired another engine out of a vanagon here in Seattle from a guy that was doing a Subaru swap. It had AMC heads and a rebuilt air flow meter from GoWesty he threw in the ECU and wiring harness as well. It had a little over 120K on it and was the perfect candidate for a rebuild.
Partial list of new parts used in the engine rebuild:
- GoWesty/AMC Heads
- Marco Mansi Oil Pump
- Marco Mansi Fuel Injectors
- GoWesty Rebuilt Connecting Rods
- Goetz Piston Rings
- VW OEM Oil Cooler
- Victor Reinz Engine Gasket Set
- Mahle Water Pump
- GoWesty Aluminum Fuel Rails
- VanCafe/RMW Silicon Engine Hose Kit
- VW OEM Thermostat Housing
- RMW Stainless Coolant Tower Junction
- GoWesty Stainless Water Pump to Thermostat Housing Pipe
cleaning and teardown of donor engine.
more cleaning
Cleaning and rebuild of the hydraulic lifters. They were all refilled with oil and bled before installing.
New/rebuilt connecting rods and bearings from GoWesty. Pistons, rings and wrist pins cleaned, weighed and balanced.
Cylinders honed and reassembly beginning to take shape.
Almost there...
Powder coated intake plenum, runners and valve covers.
Mansi Injectors and braided fuel line covers.
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
hdenter
Samba Member
Joined: October 14, 2008
Posts: 2753
Location: San Luis Obispo, CA
|
| Posted: Wed Feb 07, 2024 11:21 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
What did you use to hone the cylinders? The look a little rough...
Hans
_________________
'79 triple white convertible bug
'84 sunroof vanagon
'85 weekender |
|
| Back to top |
|
|
1988M5
Samba Member
Joined: January 23, 2016
Posts: 674
Location: Santa Cruz, CA
|
| Posted: Wed Feb 07, 2024 11:30 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
| SlalomVan wrote: |
Once I got it home, I started cleaning and building a list of parts that were needed to get it back on the road. The "rebuildable" motor that came with the van looked like it had been sitting outside in the elements for years and was in pretty bad shape. So...Craigslist to the rescue. I acquired another engine out of a vanagon here in Seattle from a guy that was doing a Subaru swap. It had AMC heads and a rebuilt air flow meter from GoWesty he threw in the ECU and wiring harness as well. It had a little over 120K on it and was the perfect candidate for a rebuild.
Partial list of new parts used in the engine rebuild:
- GoWesty/AMC Heads
- Marco Mansi Oil Pump
- Marco Mansi Fuel Injectors
- GoWesty Rebuilt Connecting Rods
- Goetz Piston Rings
- VW OEM Oil Cooler
- Victor Reinz Engine Gasket Set
- Mahle Water Pump
- GoWesty Aluminum Fuel Rails
- VanCafe/RMW Silicon Engine Hose Kit
- VW OEM Thermostat Housing
- RMW Stainless Coolant Tower Junction
- GoWesty Stainless Water Pump to Thermostat Housing Pipe
cleaning and teardown of donor engine.
more cleaning
Cleaning and rebuild of the hydraulic lifters. They were all refilled with oil and bled before installing.
New/rebuilt connecting rods and bearings from GoWesty. Pistons, rings and wrist pins cleaned, weighed and balanced.
Cylinders honed and reassembly beginning to take shape.
Almost there...
Powder coated intake plenum, runners and valve covers.
Mansi Injectors and braided fuel line covers. |
That is engine porn, bravo to your efforts and money spent. Just my simple thoughts from what I see, get the hose clamps on the fuel injectors twisted over so you can get to them with a long screwdriver.
_________________
1991 tin top GL
2002 Winnebago Vista. VW VR6 24V Eurovan front clip powered class C 21' RV.
Some BMWs. |
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Thu Feb 08, 2024 5:52 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
| hdenter wrote: |
What did you use to hone the cylinders? The look a little rough...
Hans |
Hans, I agree, the photos make the cylinder bores look much rougher than they really are. I used a 240 grit silicon ball hone and lots of oil. The cylinders didn't have any grooves or scuff marks to speak of when I started. I erred on the side of not honing too much, just enough to get rid of the surface glaze.
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
hdenter
Samba Member
Joined: October 14, 2008
Posts: 2753
Location: San Luis Obispo, CA
|
| Posted: Thu Feb 08, 2024 7:44 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
The motor does look pretty.!!! Color matched fuel line coves are a nice touch!
Hans
_________________
'79 triple white convertible bug
'84 sunroof vanagon
'85 weekender |
|
| Back to top |
|
|
dobryan
Samba Member
Joined: March 24, 2006
Posts: 16501
Location: Brookeville, MD
|
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Fri Feb 09, 2024 3:44 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
A big part of this build was to make sure the drive train was in the best possible working condition moving forward. I had the luxury of time and didn't want to slap something back together without doing what I could now to ensure its longevity. I had no idea what condition the transmission that came with the van was in. I know it leaked in all the usual places and the gear oil had probably never been changed before. So, it was a no-brainer to cart it off to Matt at AA Transaxle in Duvall, WA for a full rebuild. They are local and the best at what they do!
Fuzzy, but no big chunks...
Back from AA Transaxle, taped off and coated with self-etching primer.
Painted with couple coats of Rust-Oleum oil-based protective enamel in Machine Gray.
Mated to the engine.
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
dobryan
Samba Member
Joined: March 24, 2006
Posts: 16501
Location: Brookeville, MD
|
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Fri Feb 09, 2024 5:06 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
| dobryan wrote: |
Sodo will love that ground strap.....  |
You noticed!
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Mon Feb 12, 2024 7:42 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
I pulled the dash and removed the heater box. Full rebuild was in order. New heater core from GoWesty, new blower motor and new foam for the flaps and seals. Mixed reviews on the heater core. Supposed to be better than what was being sold a few years back, but still not blowing as hot as the stock heater core. More on that later... Lots of cleaning while everything was out of the way.
Years of dust and grime. Thankfully no rodents nests!
Old, rusty and dusty. Foam just crumbled and turned to dust.
New blower motor and painted interior metal parts.
New foam on all flaps.
New GoWesty heater core. 
All put back together and back in place. New master cylinder installed.
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
SlalomVan
Samba Member
Joined: March 28, 2006
Posts: 127
Location: Seattle, WA
|
| Posted: Mon Feb 12, 2024 7:47 pm Post subject: Re: 1989 Base Model/Blank Slate Build Thread |
|
|
While the dash was out I also took the time to clean up all the wiring and ground trees. They were a mess.
Snake pit!
Lots of dust and dirt. Thankfully no rodent's nests, poop or chewed wires.
Ground trees in need of attention.
_________________
1989 Vanagon GL - 2.1 (White - "Northlake" Totaled/Gone)
1988 Vanagon GL Wolfsburg (Orly Blue - "Poulsbo" - Sold)
1989 Vanagon G - 2.1 (White - "Kingston") - Full rebuild underway - Last on the road in 1997 |
|
| Back to top |
|
|
|
