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Getting the 1986 "Westy" back into shape!
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jimeg
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PostPosted: Sat Oct 19, 2013 11:24 am    Post subject: Reply with quote

Looking good!
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PostPosted: Sat Oct 19, 2013 12:26 pm    Post subject: Reply with quote

While waiting for the temperature to rise from the low 40's into the 60's so I could paint the engine compartment, I pulled the spare tire carrier and the radiator out..... Found more of my missing antifreeze!

I'll be putting in a new radiator, the fan shroud though........another rusty thing to clean up and paint! The motor I'll clean and lubricate before reinstallation.......

I will probably install a new temperature fan switch and wire in a manual fan switch on the dash.....just in case! .........
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PostPosted: Sat Oct 19, 2013 12:36 pm    Post subject: Reply with quote

Sadly, but not unexpected, once the radiator came out there is of course more rust to contend with. I had felt it previously with my finger tips, right behind the front bumper on the radiator side is a seam...... Yep...a RUSTY seam! About the worst one that I've found on the car thus far.......
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Also some other minor rust mostly beneath the driver area..... Better to get it now than let it eat my Van!.........
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Heavy Sigh...... Rolling Eyes

I think the key to having these units in the rust belt is a yearly crawl through program. Once a year crawl everywhere and fix any minor items such as these before they become major. That's why I do not like under coatings, they hide the rust until it has done way too much damage.

Dave
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dobryan
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PostPosted: Sat Oct 19, 2013 1:01 pm    Post subject: Reply with quote

Yep, A yearly soaking in Fluid Film or Waxoyl is a nice thing to do.... Very Happy
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PostPosted: Sat Oct 19, 2013 1:45 pm    Post subject: Reply with quote

Heck, I don't even live in the rust belt and you've got me crawling into these nooks and crannies checking mine! (Paranoid I guess).

So far, so good. There are good things about living in a desert.

That said, you have your hands on a nice specimen - and are doing a bang-up job catching and rectifying rust issues before they become problems.

Fun to watch.
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PostPosted: Sat Oct 19, 2013 6:33 pm    Post subject: Reply with quote

Nice work!

I love seeing you tear right into the things I've been ignoring on my own rig.

You're a good guy doing great things - very inspiring! Keep it up!
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PostPosted: Sun Oct 20, 2013 3:12 pm    Post subject: Reply with quote

Thanks for the encouraging words guys! I feel like I'm doing so much but there is nothing done that people notice! Ok.....no rust......cars are not supposed to be rusty! What's to see? Rolling Eyes

Well, tomorrow is forecast to be Sunny and 63*, not looking forward to it but I think that I'll suit up and sandblast off this mess, seam seal it and paint it before the rains come for the rest of the week!.......
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Heavy sigh....... Such a horrid mess to clean up......... Sad

Anyway........ Then I can reinstall my bumpers and grills and the Van won't look like a POS greeting everyone to my home! Embarassed
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I may even reinstall the headlights temporarily, just for the visual effect........... My wife is good about all of my crap but I TRY to keep it neat!.......

Dave
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PostPosted: Mon Oct 21, 2013 10:07 am    Post subject: Reply with quote

Oh yeah! Just as much fun as I had envisioned! Shocked

Anyway....the rust is gone........well, the seam rust is! I could have sandblasted the whole area but that's a job for another year! For now I'll wire brush the spots and cover with Rustoleum Rusty Metal Primer.........Only so much you can do.....right now the program is to arrest the rust, properly taking care of the major spots........
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And it is primed...... Once this dries, seam sealer and paint!........
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Dave
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PostPosted: Tue Oct 22, 2013 4:24 pm    Post subject: Reply with quote

Not much today, investigated rust on the front door step, didn't find any! Smile
http://www.thesamba.com/vw/forum/viewtopic.php?t=574369

I put the tail lights back in using Stainless Steel screws, installed the headlamp buckets using Stainless Steel screws, installed the grills and mounted the bumpers. I now don't need to store them and the Van doesn't look quite so much like a carcass in the driveway! I used new stainless steel bolts with an antisieze for the bumper mounting. The old ones were pretty well gone and made me wonder if they we going to snap off while I was carefully removing them!

It does look blind however! I just can't wrap my head around $83 for headlamp hardware!

I also painted the screws for the mouse screen and fresh air intake black so as to not be seen through the grill.

It was kind of nice digging out baggies of parts and putting them ON the VW when I've been taking stuff OFF for so long! Smile

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PostPosted: Wed Oct 23, 2013 7:15 am    Post subject: Reply with quote

Well, I've explored many options for headlight adjusters....none cover it all.

Some of the fixes rely on interior grade hardware that will rust and seize sooner rather than later........

I've a $100 credit soon for my connecting rod deposit....money that is already mentally "gone"..........

Maybe I'll just allow it to stay gone and have him send me some adjusters......that whole do it right the first time thing........ If the first set lasted 20 + years..... That's long enough for me! That's $4 per year.......

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http://www.van-cafe.com/home/van/page_1396_609/headlight_adjuster_kit_complete.html

Dave
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PostPosted: Thu Oct 24, 2013 9:14 am    Post subject: Reply with quote

Throughout life, I've found that overall honesty is the best policy.

Sometimes though....... You wonder!

I ordered a cylinder head from Bus Depot.....just one (1)....

Low and behold a delivery comes last night and inside of the box is not one but TWO (2) cylinder heads!..........
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Oh......temptation rears its ugly little head...... Unsolicited deliveries are yours to keep aren't they? But why screw Bus Depot over an honest mistake?

I shoot off an email to Fred at Bus Depot.....he's sending me a freight return ticket.......

Oh well! I was THAT close to two new heads! Smile

Hmmmm..... Maybe if I glass bead the old head.....it will look shiny and new, put it in the box............ Nah.......that wouldn't be right either! Shocked

Dave
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PostPosted: Thu Oct 24, 2013 10:24 am    Post subject: Reply with quote

Sadly....... I'm out of excuses!

Reasons not to work on the engine........

I ordered parts! ...... Ok, thats fair, it works.....

Most of the parts are here, but I'm waiting on the cylinder head.... True....

Sure I COULD do the rods, clean up the pistons, hone the cylinders, etc....but it's so warm that I will work on the body..... Excellent excuse! and it got a lot of rust problems remedied!

It's my birthday!.....
It's my twin grandchildren's birthday!......

Now.....
Birthdays are over.....
All the parts are here including the head.....
The rust is cleaned up.....
The temperatures have plummeted, and as the weather report says..... "The growing season has ended!

Time to get busy!

But! But! The garage is COLD! Rolling Eyes

Dave
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PostPosted: Thu Oct 24, 2013 10:43 am    Post subject: Reply with quote

Got heat!
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Ahhhhh..... WARM! Smile
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Dave
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PostPosted: Thu Oct 24, 2013 6:02 pm    Post subject: Reply with quote

Well, I began.......
Stripping and cleaning the head I'm reusing.

It's 39* right now.......Heat is a very good thing!

No major progress, stressful day on the home front today! Sadly, the Wife is dragging home work tensions! Rolling Eyes

Maybe there's something to that old theory that wives shouldn't work and stay home...... barefoot and pregnant?

Dave
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PostPosted: Fri Oct 25, 2013 4:43 pm    Post subject: Reply with quote

djkeev wrote:
Throughout life, I've found that overall honesty is the best policy.

Sometimes though....... You wonder!

I ordered a cylinder head from Bus Depot.....just one (1)....

Low and behold a delivery comes last night and inside of the box is not one but TWO (2) cylinder heads!..........
Image may have been reduced in size. Click image to view fullscreen.


Oh......temptation rears its ugly little head...... Unsolicited deliveries are yours to keep aren't they? But why screw Bus Depot over an honest mistake?

I shoot off an email to Fred at Bus Depot.....he's sending me a freight return ticket.......

Oh well! I was THAT close to two new heads! Smile

Hmmmm..... Maybe if I glass bead the old head.....it will look shiny and new, put it in the box............ Nah.......that wouldn't be right either! Shocked

Dave


Maybe BD would cut you a decent deal to not have to ship the head back? couldn't hurt to ask...Then you have two new heads. You're a good man to not keep that one! I'd be very tempted, though I guess with a bigger ticket item like that I'd probably end up making the same call.
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PostPosted: Mon Oct 28, 2013 10:18 am    Post subject: Reply with quote

Headlamp mounting.

As I've mentioned, the thought of spending $83 on headlamp mounting hardware disturbs me. What further disturbs me is how long will it last before it crumbles like my existing hardware? Not one piece of my 12 mounting points is reusable!

Here is what I have.......
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I've read many posts about how to make repairs and honestly some of them are good ideas. What they all fail to consider is longevity when exposed to the harsh environment that headlights are subjected to.
Massive amounts of rain, rain water thrown up by other cars, Winter de icing chemicals dissolved in the rain water water or melted snow and thrown up into the headlamp mounting all this equates massive corrosion and rust rendering many of the work arounds useless for the long haul.

These work arounds are fuel hose and hollow wall anchors, brass plumbing fittings, even soft drink bottle caps!

http://www.thesamba.com/vw/forum/viewtopic.php?t=385347

http://www.thesamba.com/vw/forum/viewtopic.php?t=456788&highlight=headlight+adjuster

http://www.thesamba.com/vw/forum/viewtopic.php?t=397173&highlight=headlight+adjuster

http://www.thesamba.com/vw/forum/viewtopic.php?t=393147&highlight=headlight+adjuster[/quote]

No, I want something long lasting, something simple, something easy to create and something off the shelf CHEAP!

I want nylon, and I want stainless steel without the fragile little connectors to each headlamp bulb.

The brass plumbing plug...... I like that idea! They screw into the housing and a thread is cut for screw with the washers to hold the lamp.....I like that Idea...... The fuel hose concerns me because of decay but not totally eliminated....... The brass plugs will corrode and seize onto the threaded screw, be it ferrous, brass, or stainless steel, I've seen this all too frequently.

Ok..... Here it is!
Nylon thread hex head plumbing plugs!
The top hex is about 1/8-3/16" thick, enough to hold a thread cut into it.

These plugs are available in a variety of sizes.... 1/8" 1/4" 3/8" 1/2" 3/4"......

I found that the 1/8" the 3/8" and the 1/2" all fit into the headlamp bucket without modifying the bucket!

Only the 1/2" plug screws into the housing, the others are sized to slip I tot he existing holes.

I need to hold the nylon plugs in....... Hmmmm..... Nuts on the back side! Brilliant!
But....
They only make a 1/2" pipe threaded nut..... Ok I'll buy them, what about the other two sizes.........
Hmmmmmmm
Bronze pipe couplers! Threaded both ends......cut a little off to make nuts!

My shopping pile........
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Ok, I need threaded holes in the nylon plugs....... Easy! Just connect the six points with a line across the center, where they all intersect is dead center!.......
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Center punch the center and drill a #3 sized hole (tap drill size for 1/4-20 threads)...........
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I used a 1/4-20 tapered tap and did not run it fully through to give some tight threads in the nylon to help prevent vibration from changing the adjustment as you drive........
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I did this for all 12 plugs for both sets of headlamps.
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Last edited by djkeev on Mon Oct 28, 2013 10:59 am; edited 1 time in total
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PostPosted: Mon Oct 28, 2013 10:30 am    Post subject: Reply with quote

The 1/2" plugs I got "nuts" for, the other two sizes, I have to make nuts.

No problem, I've got the bronze coupler..........
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I clamped them gently in the vice and sliced off both ends making a pile of bronze "nuts" for the thread sizes I need........
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I then put the nylon plugs into the holes as required and threaded on the nuts to hold them firmly in place........(all of the holes are not used)
Front side........
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Rear of housing showing the nuts.......
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I then took my 1/4-20 stainless screws (I used 3" but they were too long, purchase 2" screws) slipped a stainless steel washer over the screw head......
Slipped the screw into the hole in the lamps.......
Slipped another stainless steel washer on the back.....
And threaded on a stainless steel nylon locking nuts squeezing the lamp gently between the washers........ Loose enough to turn, tight enough to not vibrate........
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I then screwed the screws into my modified nylon plugs.........
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I mounted the assembly back in the Van.....MAKE SURE THE SCREWS DO NOT PROJECT INTO ANY WIRES BEHIND THE LIGHT ASSEMBLIES!!!!!!!!.....
And put the grill back on........
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The new screws allow you to adjust the headlamp aiming without having to remove the grill.......just like the factory design!....... You can see the screw heads visible .........
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Material list.......
6 - 1/8" Nylon Plumbing Plugs
2 - 3/8" Nylon Plumbing Plugs
4 - 1/2" Nylon Plumbing Plugs

3 - 1/8" Bronze couplers
1 - 3/8" Bronze Coupler
4 - 1/2" brass nuts from the plumbing supply house

12 - 1/4-20 x 2" Stainless Steel Phillips Headed Screws
12 - 1/4-20 Stainless Steel Nylon Lock Nuts
24 - 1/4" stainless Steel a flat Washers

#3 drill
1/4-20 Tap
Hacksaw
Pliers, Screwdrivers and wrenches as needed.
Drill

The whole supply pile set me back maybe $25. Still a fair amount of coin but consider this will last for a mightily long time! If it does fail, it will be a $1.50 Nylon plumbing plug! You win't be buying $83 worth of hardware yet again!

Enjoy!
Dave
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big swifty
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PostPosted: Mon Oct 28, 2013 4:27 pm    Post subject: Reply with quote

GENIUS.
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PostPosted: Mon Oct 28, 2013 4:46 pm    Post subject: Reply with quote

x2! This goes into the long-term "SAVE" file!

Keep it up! Can't wait to see how you handle tan corduroy... Wink

- Dave
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PostPosted: Tue Oct 29, 2013 4:17 pm    Post subject: Reply with quote

Thanks but really none of this is my idea. See the links I referenced earlier.

I simply took portions of what other people did, changed the materials used and reassembled it all in what I consider a "better" manner.

Dave
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