The Build Thread of Lostfalia, narrated by SpeedoJosh

[SpeedoJosh]

So..... I picked up Lostfalia back in July (Trip report - http://www.thesamba.com/vw/forum/viewtopic.php?t=525290) Since then, I have been planning on a much needed trip/vacation for an undetermined time while carrying my beloved XR250R, (650R is going to have to stay behind on this one.) So I started checking things out and ordering parts.

Sean from Transporter Werks and Karl from Westy Ventures both showed me and told me about me some Vanagon commons. So I took some stuff from that list, and added it to mine, and got the ball rolling, and the credit card building.

Yakima Rack system
BusDepot SS coolant lines
TF49
Burley Heavy Duty Hitch
Motorcycle Hitch Mount
Jack Bombay Top Shocks
Solar set-up

Then a bunch of other little things that were needed:
Oil change
Coolant
Find out why gas pedal is sticking
Find out weird whine noise that increases with speed
Find spot for spare tire
Figure out how to help with a motorcycle being on the back of the van
Find a better way to mount the stereo components


Guess I’ll just start at the top.
Yakima rack. Picked up the 1A Towers, Wide Body Brackets, 2x 78” bars, and a 56.
There is a shop here that has lifts, and you rent the lifts hourly, so off I went.
First thing first I changed the oil. No need to take a pic of that.
Next, I used the lift as a ladder and started on the rack. I was doing three bars, so I spaced them at the three common locations. Far back, just after middle indention, all the way forward. Shop only had a pneumatic drill (WTF) but I made it work.

I measured 3x, and drilled twice. First drilling, the holes were too small, so I just popped in a larger bit, as recommended by Jeff (Vanagon Travels). I used his write up quite a bit. Helped a lot.

Comparing the smaller holes with larger

I used wood to support the top in the up position, and also used pieces of wood as backing, so when the drill bit pushed through the fiberglass, it didn’t also push through the cloth top.

I drilled the holes, then applied silicon around the holes

Then placed the bracket down. Then placed silicon on the back side, on the washers.

Then once it was all said and done, I ran a bead of silicon down the top of each bracket.

Mounted the towers/bars, and dy-no-mite.

While in the shop, I also figured out while the gas pedal was sticking. The plastic sheath that covers the throttle cable was getting hung on the gas pedal assembly in the black box. So I just filed down the plastic sheath. Much better.


With those done, next is the coolant lines. Well, the Bentley manual was confusing me, and I didn’t have a spare body to hold the 2k RPM while I bleed the system, and added coolant, so I digressed to something else. Burley Hitch arrived, lets do that.

Pretty easy install, remove old bumper, then slide in new hitch. I recommend you have a rubber mallet on standby as I had to whack mine a few or 300 times to get it lined up perfectly for the holes.

Old bumper off

Bare-assed Losty

New hitch itch’n to go in

Installed

Got it all and after jumping on it without it moving, I threw the moto-hitch on there

Then the 250.

Rear is hanging kind of low, not fun since the Zetec already hangs low. Currently researching rear suspension changes. Either Syncro.org springs with a spacer, or full airbag suspension. At the moment, I’m kind of siding with the syncro.org springs due to no cutting/welding needed.

To be continued. Much more on list to follow..............

[SpeedoJosh]

I got sick in the middle of all this, and was down for 2-3 days with fevers and what-not. Although, I got board around day 2 and went out and started poking around the old domestic. I had the TF49 on standby, but was going to wait until I left NC (couple weeks). Well, after poking around, I started removing a screw here and there.

Next thing I know, fridge is out.

Soon to be resting place of TF49

Used a hacksaw and cut this top part away, as per recommendation

Tucked this little guy away as per recommendation as well.

Went to relocate my outlet, but come to find out, the previous owner cut it, so it wasn’t connected anything. So I just removed it entirely. Not sure if it’s needed, or just liked.

I read through hours of threads about fridge install, but for some reason I was still confused. (I blame the fevers). Anyway, I stopped with the fridge, and went back to the coolant lines since I was feeling better.

So popped old coolant lines off, took a shower in anti-freeze, and started putting the new Bus Depot SS 2 piece ones on.
Here’s where I took the shower from

New pipes waiting to go in, with the ever so precious Bentley manual on standby.

Comparing new vs old.

I bought the two-piece b/c you don’t have to lower the tank. Well after about an hour of trying to get the second pipe in, I call Bus Depot. Here’s the response I got, “I’ve never installed those, and I can’t find the email instructions, Sorry.” Gee thanks! So I went to The Samba for guidance, and found out it’s a common problem to get them in there, and someone mentioned they called Van-Café and they instructed lowering the tank just a couple inches, and they’ll slide right in. Did that and Yahtzee, in they went.
Thanks Van-Café!

So new lines in and here comes the fun part, bleeding the system. I was equipped with a Bentley, so I was ready. I lifted the front of van, opened bleeder screw, open heater vents, and started filling the coolant. Once it wouldn’t hold anymore, I followed the instructions and started the van, and rev’d to 2k, expecting air to come out of the radiator, and coolant level to drop in the holding tank. Well, the Zetec is setup different, and coolant starting boiling out of the holding tank. Erupting is actually a better choice of words for what was happening, and anti-freeze was turning the rear of my van into Pompeii. Shiz. Turned off the van. Called Bostig (Awesome support, can’t say that enough. Owe you guys pizza if you’re reading this) to see if I was missing something, and was told all that was unnecessary. Just fill it, drive it, open bleeder until no air, close bleeder and refill holding tank. Too easy, van running great now.

Also, threw the spare up under there.

Realized with the spare, it makes it tough to shift into reverse, not sure why???? Also, is that spare tire cover needed? I just have the spare mounted up with the drop down swing bracket, but no cover.

[jackbombay]

What is the brand on that moto rack? Looks like its easier to use than the typical ramp, platform set-ups, is it pretty easy to use? I have an XT 225, ~250 pounds full of gas and oil so pretty close to your honda, mmmmmm Honda.....
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Gas struts to pop your top easily!
Pop Top strut kits now available for late Bay window Westies

Samba ad here.


DIY artificial rain gutters (ARGs)

[BillM]

You have what looks like a van-cafe spare tire bracket. There
is no cover. Your reverse issue may be the spare is in
the way. Try lowering the front by using a couple washers
under the bolt. Just be sure the bolt has enough threads
into the fastner if not you will need a longer bolt.
Also a pet peeve as I use a lot of tie-wraps is to trim
the end flush with the lock tab. That way there is nothing
sharp sticking up to cut anyone plus it looks neater. A set
of Xuro shears work great for that if you have a set.
As you learned bleeding a zetec install is easy. Not that
a stock system is difficult just more time consuming. I
use a airlift now. Great tool to remove air and force
coolant into all the right places.
When I installed my TF49 I used angle aluminum and
slotted the mounting holes. It made it easier to get the
fridge all the way to the top of the opening without having
to shim it. I also chose to remove the rubber feet and put
strips of EPMD weather stripping on my angle supports
to prevent vibrations. I am not a woodworker and hate
having things look hacked up. If I was able to pull of
a TF49 install anyone can. If you want any measurements
or pictures of how I did it drop me an email address.
I also have a zetec conversion and so far it's been a trouble
free engine. Dealing with Bostig is great and makes you feel
spoiled when you try and get support from another vendor
to only find they could care less.
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Bill M
87 Westy

[SpeedoJosh]

[presslab]

[SpeedoJosh]

After the coolant lines, I started looking at the fridge again. Karl sent me an email of pictures that helped great, and off to home depot I went.

Was going to do the aluminum angle for support. Wood frame to screw the fridge into. Instead of cutting the laminate up, and messing with that, I was just going to screw the fridge into the wood with no laminate. Can always add the laminate later, plus I didn’t have the space or tools to work on the laminate here. So I bought all the gear, and off I went. I measured everything out. (All work was done at night, so pics are kind of hard to see.)

First thing first. Redman Silver to turn me into a Sexual Tyrannosaurus (Sugarfree b/c it won’t give you diabetes while it gives you cancer.) I only chew when I am out in the woods and going on no sleep for over 24 hours, but found this bag in my kit, so figured “What the hay”.

Next of course is the jams

Cutting out the aluminum supports in my metal fab shop

Quick shot of the size incase someone is wondering

The rubber strip I glued to the aluminum angle to stop rattle, and protect the bottom of the fridge.

Then went onto cutting the wood frame in my wood-working shed

Then test fitting the frame

Fit pretty good, just a little sanding needed for smooth edges
My sanding station. Pretty cheap set-up, think you can pick them up at any store

Then the finer sanding station

Final test fit of frame before paint

Time to paint the frame in my shop’s paint booth

Black frame – ooohhhh, awwwwww

With the frame in place, I started test fitting the fridge to get the height of the aluminum supports.

Used tubberware initially, then from there, I measured how far I was from the top, and went and made a wood spacer

With tubberware and wood spacer I was looking pretty good.

So I marked where the wood was at, and that would be my aluminum angle mounting line. (I know I could of gone another 1/16”, but I wanted to air on the side of caution, and not get it exact incase of an unforeseen interference.

Next was to drill out holes for the hardware.
Quick mock up of where I would want the bolts to mark where to drill

All drilled up

I placed/held the aluminum angle on the line marked for them, and marked the holes, then drilled away.

First bracket in

Came a little close to the propane line, but it squeezed in fine. (Yes, I know, I should of installed the bolts the other way around. Realized that after I installed.)

I kept hitting some stupid piece of plastic that was hanging down, so I removed it. No idea what its intended use was.
Peek-a-boo

In the process I knicked my knuckle

Oh my gosh, there’s so much blood

Turning the van into a crime scene

Ok, much better. Back to the brackets now.
Other side in

Had to leave the middle one out since the battery is in the way, 4 is enough though.

Interesting fact. The back side, or left, is a lot thicker then the other. Bolts barely fit. I ended up only able to use one washer. Like an idiot though, I put it on the wrong side, should of mounted on the back side of the wall to distribute the load. I’ll fix that when I turn the bolts around.
I used ¾ Grade 8 bolts (all the hardware store had enough of), large washers on both sides, and lock nuts to secure in place.

All done and ready for the TF49

I glued down rubber strip, from a door threshold, to act as a noise dampener, and so the fridge wasn’t resting on straight metal. The feet just miss the aluminum support.

Rubber strips

Fridge in place

With this set-up, I have almost exactly 5” from bottom of fridge to the floor. Hope that’s enough for a Propex. Measurements online show it at being 4” tall, so just about an inch of room above.

I removed the water fitting in the back, will come up with a better solution later. Also, I tried to plug the 3/8 fitting on the propane line, but the plug didn’t work. Plus, I think I might of stripped it out. FML. Luckily Karl from WestyVentures is a badass, and is sending me a part that I desperately needed.

I also semi figured out what the wine is. It’s something electrical. If I turn off my radio it goes away, but with the radio on, I hear a very audible whine, that increases and decreases with accel/decel. Guess I’ll get that sorted after I research/study stereos for a couple days, so I can attack the current stereo situation.

Got my top shocks in, will be installing those shortly, and adding pics for those that are actually still reading my babbles or people looking for pics of it.
Jack is awesome to deal with, and helped out greatly. Real stand-up dude.

Well, that pretty much finishes my list. Only big thing left is the solar set-up, which I am researching heavily. Thinking I’m going to do a 120watt panel, to two golf cart batteries, and put them under the back seat. Going to have to remove the heater though. No big deal though, as I plan on getting a Propex. Plus, I live in Florida.

[FNGRUVN]

I bet with a 120w panel you could get by with just one 12v deep cycle battery to save room and make wiring it up a little easier. Also, I'd hang onto that fiberglass rear bumper if I were you. I noticed yours was cracked. They can be repaired and they're getting harder to find.

BTW You do better work in your parking lot with the bare minimum of tools than some guys do with a fully stocked car shop. Keep up the good work and fun to read posts.
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"Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." - Benjamin Franklin

[SpeedoJosh]

Thanks for the words.
Yea, I currently have two marine batteries, but they're optima, and only putting out about 60AH a piece. Would probably be plenty if I had a 120w panel. The golf cart batteries are 250AH each, and you run two since they're 6v, so that'd be a lot of battery life. So I'll probably end up with those sooner or later. The stereo system in this thing is crazy, so plan is, once I finish moving my stuff down to Florida is to remove the under the seat heater, then rewire the stereo system. That way, I can get ready for the solar set-up and propex, then be done with goodies, and go into maintain mode.

There's a VW guy around here that has a couple Vanagons that are pretty much part vehicles, going to try and snag a bumper and round headlight assembly from him. My bumper, I fear, is too far gone. Doesn't look too bad in pics, but it's about to break in two, and has already been patched multiple times. The mounts fell off while I was removing the bumper from the van. It's pretty bad.

[SpeedoJosh]

Just picked up these goodies.

More should be arriving in the mail shortly.
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87 Westfalia 2wd
Bostig Conversion
Build thread >> http://www.thesamba.com/vw/forum/viewtopic.php?t=529709&highlight=

[benandmj]

Where you at dude? Update us! This is a great build!
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85 Westfalia Weekender
91 Syncro Westy

[nemobuscaptain]