The Dharma Bus

Jockomo · Posted: Thu Mar 22, 2012 11:13 am Post subject: The Dharma Bus

Finally starting a project thread for my bus.

I know, such a cliche name, but honestly it was named this at least 10 years before "Lost" came out. Our band was named Dharma and the bus carried our gear. Needless to say we all flipped when we saw the bus on Lost.

Anyway, it's a 75 Westy. It was originally from Germany and the owners got it over to the states somehow. From what I understand the bus caught on fire on I-10 just outside of our town. It sat in a junkyard for 10 years before the PO got it and put a too small engine in it (don't remember exactly what)

Sometime around 98 I put a 2L 78 engine in from GEX and scrounged parts from another engine I pulled from a junkyard. Did some great trips in it back then and then sometime around 03 I decided to drop the insurance because I had another daily driver.

So now the daily driver has given up the ghost and it's time to bring the bus back to life.

Below are some pics

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

I've had a problem lately, that I think is a leak in the clutch area. I found alot of what looked like oil or transmission fluid in there and I think that was making the clutch slip. I have a new seal for the trans and a one for the engine otw.

So I have the engine out and on a stand.

And I'm wondering, is it ok to rotate the engine and leave it in whatever position I need it in? I hope so, because it's been sitting like that. (the oil has been drained)

I took the heads off to check out the condition of the valves.
Here is what I found:

First, I see this doesn't look quite right. Shouldn't I have a spring between there instead of a spacer and those older spring washers?

Anyway here is my head:

And one of the pistons, other is about the same.

My plan at this point is to remove the valves and get them clean to get a better look at them and clean up the rest of the head.

I'd also like to clean the piston top, from what I understand if I can keep the sleeve seated in the engine body and move the piston to the end of the sleeve and clean it off. Maybe this is not even needed, I'm not sure.

I'm already into a bit of unknown territory at this point and could use some advice as to how far I should take this inspection and cleanup.

Also the best way to clean the valves/etc.

I've got a new can of berryman carb cleaner, I plan to do that for about an hour for each part, then rinse with water and spray with wd-40 to keep rust free till reinstallation. Is this ok, any problems with mixing the WD-40 with the motor oil once it's installed?

Thanks

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'75 Westy with '78 2.0L engine.

curtis4085 · Posted: Thu Mar 22, 2012 12:04 pm Post subject:

Spacer I believe is common for hydraulic lifter setup. I could be wrong but my 79 with hydraulic lifters has the spacers.
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Jockomo · Posted: Thu Mar 22, 2012 8:24 pm Post subject:

I've got the head much cleaner. But I'm a bit wary about pulling the valves.
Having never done it before. I have an overhead valve compressor but I'm concerned that I'll screw something up. Should I be?

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'75 Westy with '78 2.0L engine.

RatCamper · Posted: Fri Mar 23, 2012 2:30 am Post subject:

Jockomo · Posted: Fri Mar 23, 2012 8:11 am Post subject:

Got one out. I was using the OEM Brand overhead valve spring compressor on loan from AutoZone. It sucks, at least for this. The way the tool fits the over the spring retainer doesn't work for these valves.
I had previously picked one up from Harbor Freight, and was going to return it since I hadn't opened it yet. But it happens to work great.

You can see how they compare, OEM on the left and HB brand "Pittsburg" on the right.

The HB also is built to fit the springs better with offset arms, plus they're spring loaded.

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'75 Westy with '78 2.0L engine.

Jockomo · Posted: Fri Mar 23, 2012 12:47 pm Post subject:

Just found a bonus pair of exhaust manafold gaskets installed. Explains why they never fit right.
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'75 Westy with '78 2.0L engine.

chabanais · Samba Member Joined: July 27, 2002 Posts: 4866

Is your lump still based on the GEX case?
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"I spud therefore I yam."

Jockomo · Posted: Fri Mar 23, 2012 1:42 pm Post subject:

chabanais · Samba Member Joined: July 27, 2002 Posts: 4866

"Lump" is slang for engine, motor is slang for car.

GEX doesn't have the best reputation around these parts, hope yours is the exception.
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"I spud therefore I yam."

Jockomo · Posted: Fri Mar 23, 2012 6:18 pm Post subject:

Ah, thought that might be the case.

Anyway, the first head is all back together. I pulled all the valves and cleaned them and the seats up. I think they look ok. No damage anyway from what I could tell.

I did find that I was missing a flat washer for the #2 rocker arm. Anyone happen to have one of those laying around? I'd gladly pay for it.
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'75 Westy with '78 2.0L engine.

chabanais · Samba Member Joined: July 27, 2002 Posts: 4866

Might want to ask your question here:

http://www.thesamba.com/vw/forum/viewforum.php?f=12
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"I spud therefore I yam."

Jockomo · Posted: Tue Mar 27, 2012 8:58 am Post subject:

I picked up an engine gasket kit from Victor Reinz.
There is no list of what parts are in the kit, but it is sorted into a few different bags.

I'm trying to figure out what some of these are for.
Specifically it came with 3 sets of 4 gaskets that are all about the size of the cylinders. Two of them are for the cylinders i'm sure, and I can match those to the old gaskets pretty easy.

But there is the third set, they are very thin, like 1/4 the thickness of the cylinder gaskets but very slightly larger in diameter.. Almost more like shims.
Are these shims for the flywheel?

It's part number 17-00121-01 I see another samba thread with that number, but no answer. Any clues?
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'75 Westy with '78 2.0L engine.

Jockomo · Posted: Tue Mar 27, 2012 10:28 am Post subject:

ah here it is: http://www.ratwell.com/technical/GasketSet.html
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'75 Westy with '78 2.0L engine.

Jockomo · Posted: Thu Jul 19, 2012 11:01 am Post subject:

Very pleased to say that my bus is now running again.
Huge thanks to the fine folks here!

replaced:
all the shift couplings
CVs,
Transmission gaskets+ the little ball that the hockey stick fits into
Rear final drive seals
main drive seal
alternator wiring harness
main wiring harness
new pertronix svda and coil
rebuilt my weber progressive, with new jetting
clutch and pressure plate,
and more...
The make it go stage is done, now to make it stop Smile

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'75 Westy with '78 2.0L engine.

Jockomo · Posted: Thu Oct 17, 2013 7:11 am Post subject:

A few more pics:

Added a sprayer to the sink. Perfect for washing sand off your feet at the beach or as a shower. Fits outside the little window with the door closed.

Interior arrangement.

Stove Closed

Stove Open

The original German Plate (It lived its first 8 years in Germany. I would love to connect with the original owners and let them know its still kicking and happy)

Caravan Rally emblem from '79 (was glued to the roof interior when I got it)

Its been to some shuttle launches as well. Space Lab 1!
I wish I knew how to protect these from fading and falling apart.

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'75 Westy with '78 2.0L engine.

Bala · Posted: Thu Oct 17, 2013 7:28 am Post subject:

Congrats on bringing it back to life. You have a nice one!
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1976 Westy

1966 Beetle

Jockomo · Posted: Fri Feb 13, 2015 6:17 pm Post subject: New Heads

Some of you might remember my encounter with this custom insert.

Seeing how big it was, I decided to get new heads.
This is inside the old head with the insert.

I have several questions, but to start with:

What should I use when installing these bolts that are normally found on the head? (loktite?). What should I torque them to and what's the best way to do it?

Thanks!
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'75 Westy with '78 2.0L engine.

busdaddy · Posted: Fri Feb 13, 2015 8:20 pm Post subject:

I don't se any stickers proudly displayed, are those straight out of the box?, or have they visited one of the qualified type 4 head rebuilders for a tweak before you install them?
How about compression?, doing any calculations yet?
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kevin77westy · Posted: Sat Feb 14, 2015 1:15 pm Post subject:

OOOoo.. Pretty. I just double nut them and snug them down real good. I have never used Loctite or anything.

cliveawn · Posted: Sun Feb 15, 2015 10:33 am Post subject:

Thats a nice Helsinki bus,I have the same one and have been told they are rare and the Rolls Royce of VW campers.
Does yours have the Truma gas heater?
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Green 78 Westfalia Helsinki,

2056 with 41 x 34 valves,ported heads
Fully balanced
8,5:1CR
JPM Custom made cam
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115 HP

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