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Bostig / Zetec Turnkey Install
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indytriple
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PostPosted: Fri Dec 21, 2012 8:36 pm    Post subject: Bostig / Zetec Turnkey Install Reply with quote

My Bostig Turnkey kit showed up today. I figured I'd start a thread for curious onlookers.

Christmas came early at our house!

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The contents:

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Bentley, Haynes and now...Bostig

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Unfortunately, I can't move forward with the engine install until I'm done resealing the entire transmission. It's a leaky mess.

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The transmission sealing is taking place on this thread:
http://www.thesamba.com/vw/forum/viewtopic.php?t=401180

The tranny seals should be here from Van Cafe at the end of next week.

I'm going to do a few things in the meantime like fit the airbox, mount the coolant overflow and the power steering brackets, etc. I'll post pictures of that stuff as it goes along.
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comet42
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PostPosted: Fri Dec 21, 2012 9:13 pm    Post subject: Reply with quote

Christmas, indeed. Keep the photos coming! Looking forward to seeing how this turns out, Indytriple..
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0to60in6min
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PostPosted: Fri Dec 21, 2012 9:17 pm    Post subject: Reply with quote

nice..

put your nose in the box and smell the new engine..

once in the van....

Merry Christmas
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t3 kopf
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PostPosted: Sat Dec 22, 2012 4:24 pm    Post subject: Reply with quote

funny, the first thing i noticed was the phish sticker. sure wish i still lived up there and could go to deer creek again. went there ten times at least in my old vanagon and the one time i went in a regular car, it broke down. go figure. enjoy the new kit! take it up to MSG this year....and pick me up too.
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PostPosted: Sat Dec 22, 2012 5:01 pm    Post subject: Reply with quote

NavyVW wrote:
funny, the first thing i noticed was the phish sticker. sure wish i still lived up there and could go to deer creek again. went there ten times at least in my old vanagon and the one time i went in a regular car, it broke down. go figure. enjoy the new kit! take it up to MSG this year....and pick me up too.


same here--first thing i noticed. Smile good see that we have some phans on the board.

looking forward to watching the install process.
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indytriple
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PostPosted: Sat Dec 22, 2012 5:24 pm    Post subject: Reply with quote

NavyVW wrote:
funny, the first thing i noticed was the phish sticker. sure wish i still lived up there and could go to deer creek again. went there ten times at least in my old vanagon and the one time i went in a regular car, it broke down. go figure. enjoy the new kit! take it up to MSG this year....and pick me up too.


porterbrown wrote:
same here--first thing i noticed. Smile good see that we have some phans on the board.

looking forward to watching the install process.


I used to run a website 15 years ago that was the "clearinghouse" of information about seeing Phish at Deer Creek. It had details on camping and inside info (like how to avoid the Hamilton Cty. PD traffic stops). That was back when they were estimating that 50,000-80,000 phans were in the surrounding campgrounds and the venue only held 18,000. Now the corn has gone away and the vinyl villages have popped up like mushrooms. Ah, those were the days...

Here's a thread I started a few years ago that involves Phish, Deer Creek and my broken down Westy...
http://www.thesamba.com/vw/forum/viewtopic.php?t=427491

Turns out it was a dead ECU, but we made it to the show anyway! We camped in the Westy with the kids at the Deer Creek on-site this year in the 106 degree heat and crazy thunderstorms. I've seen every Deer Creek show except the night my daughter was born in 2009. We streamed the show at the hospital. She was born during a late-night Tweezer Reprise encore after the show was delayed for thunderstorms. Saw my first Umphrey's McGee show at Dead Creek Campground in '99. Great memories. Hopefully we can hook up at a show sometime.

I would have loved to have had my Westy fifteen years ago when I used to go on tour in automobiles like an '82 Buick Electra or a '90 Ford Probe. Tour would be a snap now with all of the creature comforts. We may try a short run next year with the kids.
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indytriple
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PostPosted: Sat Dec 22, 2012 5:56 pm    Post subject: Reply with quote

Here are some more pictures of the goodies...

SCT Flasher. This is optional with the turnkey or any Bostig kit. The tunes are already loaded onto the unit by Bostig.

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


OBDII Extension Cable. This is also optional with the turnkey or any Bostig kit. It will allow me to plug into the OBDII port up at the front of the van somewhere.

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A little bit of Ford/VW humor from the Bostig boys.

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Here's everything that comes with the turnkey that isn't already installed on the engine or the peripherals.

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Here's a better shot of the engine after the packaging material and small parts were taken out. Every hose, cable and piece is carefully labeled with basic instructions as to where it goes. If you were ever worried about doing an engine conversion without much prior knowledge or experience, this thing is about as idiot-proof as it gets. It was test-run on the crate at Bostig and had the proper tunes loaded onto it. If you hooked up a battery and a fuel source to it, it would run.

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All of the parts are very neatly bagged and labeled. Some of them also have helpful hand-written notes on the bag.

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The quality of everything so far seems top-notch.

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It didn't obviously come with the Bostig kit, but I'll be installing a new GoWesty gear reduction starter.

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I bought a 25 foot spool of J30R9 fuel hose off Amazon for a smoking deal. I'll need at least half of that or more for the replacement of the fuel lines (including the plastic send/return lines), but I'll have a bunch left over to keep around.

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I also heard from Jim today. He told me that it was no problem bugging them over the holidays if I ran into any problems with the install. They've been nothing but prompt and helpful so far.

Onward and upward.

I'm going to keep all of the photos in this gallery in case anyone wants to see more or wants to look at a photo in its original full-size state for detail.

http://indytriple.smugmug.com/Cars/Bostig-Install/27168250_pQkvQv
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Phishman068
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PostPosted: Sat Dec 22, 2012 7:13 pm    Post subject: Reply with quote

I looked on amazon and found no such "smoking deal". Any links?

Aweosme man! you'l love the zetec.
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t3 kopf
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PostPosted: Sat Dec 22, 2012 7:38 pm    Post subject: Reply with quote

read the writeup about deer creek 2010. hard luck. at least you were somewhat a local. i used to live in southern illinois. my first show over there was in 99 and i rode in a windstar after an attempt to go in my buddy's 71 westy which threw a rod after about 50 miles at 65 MPH.
the next tour in 2000, i had an air cooled '80 vanagon and she was a beast. took me to deer creek, nashville, columbus and cuyuhoga falls (later that year). after she went on to greener pastures i attempted deer creek again(2003 i believe) in a grand am and hit a stump somewhere in the campground which sent my radiator plug into my radiator. still made all the shows. luckily, a good mech in noblesville was able to fish it out and fix er up for me for 100 bucks. several other shows at deer creek between and after, but have not been back since i joined the navy and live in florida now. i did get to go to chicago and charleston in 2010 and went to the STL show last summer after i got back from an 8 month deployment. it was a little after that i got another van.
and now i realize i am rambling and turning your awesome bostig thread into a phish thread. haha, good luck with that bostig and hope to see it out at the show sometime. im sure it can throw down against some of those clunker vans that joe wookie drives around selling grilled cheese out of claiming it runs off of dreams and miracles Wink
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PostPosted: Sat Dec 22, 2012 8:56 pm    Post subject: Reply with quote

You are gonna love your new Zetec!
28,000 on mine with only one hic-up. (a broken flex coupling which Bostig replaced no-charge, including a brand new cat!)
Many happy miles touring the countryside!

ps..their kits just get better and better.
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PostPosted: Sun Dec 23, 2012 9:22 am    Post subject: Reply with quote

Great choice on opting for the SCT reflasher. It makes
loading tunes or data logging very easy.
Don't ever be hesitant on calling Bostig for help. It's what
we paid the big bucks for. Plus it helps them track issues
people have and let's them know where changes may need
to be made.
If you want I can take pictures of where my OBD port is
installed. Looks like it came from the factory.
I would also suggest purchasing a scan guage at some
point. With the modern OBD interface it's easy to just
plug in and be able to moniter what's going on in your
engine compartment. I tried one of the cheaper 70.00
units offered on the net and its junk.
Have fun with the install. Don't over think anything and
you will be driving real soon.
Feel free to drop me a line if you need pictures or anything.
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insyncro
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PostPosted: Sun Dec 23, 2012 10:25 am    Post subject: Reply with quote

Looks like you made Santa's nice list for sure.
Enjoy.
Turnkey is the way to go.

Happy Holidays
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indytriple
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PostPosted: Sun Feb 24, 2013 8:05 pm    Post subject: Reply with quote

I've been pretty absorbed by my transmission reseal project (http://www.thesamba.com/vw/forum/viewtopic.php?t=401180) so I haven't made as much progress on the Bostig as I would have liked. I did get a chance to do a few things today.

Here is the Westy back seat taken out to feed the new wiring harness through to the engine bay. There's no way you could do this without removing the seat. The wiring harness is already installed onto the engine with the turnkey kit, so you need to spend a few minutes detaching it before you can install it into the van.

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Here I am gently feeding the harness through the body.

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Here it is coming through the other side.

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Here is the ECU mounted up and ready to go.

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Here's a shot of the new wiring harness near the "black box".

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Snapped into place on the firewall.

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New placement of body grounds.

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Harness zip-tied to frame rail.

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New harness plugged into black junction box.

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Wiring to starter zip-tied behind firewall.

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Wiring to fuel pump.

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Everything is carefully labeled in the turnkey kit. Pretty damned foolproof.

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Area behind right tail light cleared out to make room for Bostig air box and snorkel hose.

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Using a Dremel wheel, I cut off a ~1/2" long metal post that was here that used to hold the plastic divider in place. It gets in the way of the new air box.

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I also installed the ceramic/metal heat shield that goes on the underside of the deck lid.

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Patiently waiting for the heart transplant.

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Transmission should be wrapped up in about a week or two, and then it's showtime!
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PostPosted: Tue Mar 05, 2013 9:47 pm    Post subject: Reply with quote

Everything is in, and I'll be doing my first runs tomorrow. Pictures to come.

The one thing that has me stumped is the starter wiring. I'm replacing the stock starter with a GoWesty gear reduction starter.

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


There is also a post terminal underneath the black plastic cap in the picture.

I know that the large cable from the battery goes to the main post. I also know that the two original white plugs with red wires get plugged into the black "harness" that comes with the starter.

I need to know where to hook the cable from the alternator, and I also need to know where to hook the cable from the post in the black box in the engine bay. I'm assuming that they all go on the main post, but I don't know what the post under the black plastic is or if I should use it.

Any help would be greatly appreciated. That's about the only thing left I have to figure out before I turn the key.

To say I'm excited would definitely be an understatement. I may have to go for a snow drive tomorrow.
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JeffRobenolt
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PostPosted: Wed Mar 06, 2013 7:06 am    Post subject: Reply with quote

Congrats.

I'm hoping for a video clip of it running tonight!!

You'll have all the bugs worked out for BBTB, right?

Jeff
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PostPosted: Sun Mar 10, 2013 11:19 am    Post subject: Reply with quote

Alright, what's going on?? We should of had some vids of it running by now!!

Did you run into any problems?

Jeff
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PostPosted: Sun Mar 10, 2013 11:46 am    Post subject: Reply with quote

indytriple wrote:

There is also a post terminal underneath the black plastic cap in the picture.

I know that the large cable from the battery goes to the main post. I also know that the two original white plugs with red wires get plugged into the black "harness" that comes with the starter.

I need to know where to hook the cable from the alternator, and I also need to know where to hook the cable from the post in the black box in the engine bay. I'm assuming that they all go on the main post, but I don't know what the post under the black plastic is or if I should use it.


Post under that black cap is just the mounting point for that main post. You won't use it, as it's the same as the main post. You will mount the alt and and power wires to that main post. The starter trigger wire go the plug(s).
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PostPosted: Tue Mar 12, 2013 10:17 am    Post subject: Reply with quote

Success!

The engine is in, and everything is going really well. I ran it around town here for a little over a hundred miles, and then I put it through the ringer. I was getting it ready to run mobile support for a cycling race that we run in the Hoosier National Forest in southern Indiana (http://www.sub9deathmarch.com). After the 100 mile "break-in" I drove it 70 miles south for the event. I then proceeded to drive it very hard in tough conditions for 140 miles on very hilly, muddy, gravel roads. I came home last night with almost 375 miles on it so far.

Here are some pictures of the install:

Mating the transmission and engine. I had to bend the transmission dipstick quite a bit at the end to get it to line up.

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Ready to go under the van.

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Sliding it under the van on a piece of cardboard.

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Here are some pictures from the event:

Here's the engine peaking out from underneath the back.

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Providing riders with support.

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Both of my vans provide support at the event. Here's my Carat with the Westy.

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Participants route planning while enjoying some liquid refreshment.

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Miles and miles of beautiful, scenic roads. Great testing ground for the new powerplant.

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Not a garage queen. These vans were meant to use hard!

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Bostig Represent

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I am extremely pleased with my decision. The Bostig seems to be everything it is cracked up to be. The increase in power isn't overwhelming, but it is very noticeable. The only downside to the conversion for me is slightly less ground clearance at the cradle. I lost an inch and a half, and it was a bit noticeable in particular situations this weekend. I had to drive through lots of creek crossings and light off-roading situations with rutted doubletrack. I scraped the engine cradle and the HC oil pan slightly on a few occasions. It doesn't appear any worse for the wear, though. I'm going to put a spring pad spacer on the left rear to help with the Westy lean (it's even worse now) and to get a little bit of ground clearance back. The ground clearance isn't by any means a deal-breaker. The benefits of the conversion far outweigh this disadvantage (for me at least). I could lift the van, but then it wouldn't fit in my garage which is not an option.

I still have a few issues to sort out. The speed sensor near the passenger CV has given me some issues. I originally got it too close to the speed ring, and it snapped off about 50 miles in. The good news is that my MIL (check engine light) works. As soon as the sensor snapped, my light came on. I plugged in the SCT and pulled the speed sensor code. Looked under the van, and there was the sensor dangling and snapped. Within 5 minutes of the light coming on I had diagnosed and found the problem. This is NOT what I'm used to with waterboxers! Jim is sending me a brand new tune that they are testing that eliminates the speed sensor all together. This is just another benefit of the Bostig.

I also have a whistle coming from somewhere when I shift from Park to Drive or Reverse. It only happens when the van has been running, and it is warm. As soon as I put it into Drive or Reverse I get a distinct, fairly loud whistle sound. It usually only lasts a few seconds until I start moving or give it some gas. I'm putting my money on the transmission, but I'd be eager to hear suggestions. Pump fluid starvation perhaps? The fluid level in the tranny is perfect.

I think I'm going to allow for more cable pull at the accelerator. The kick-down works, albeit reluctantly, and I have to really floor it to get it to work.

I'm going to switch back to the stock transmission mount. I put on the Bostig Heavy Duty Transmission mount. I was warned ahead of time that some people notice significant amounts of vibration when using it with the auto tranny. I decided to go for it instead. Well, unfortunately they were right. It's not a showstopper, but the guys at Bostig tell me that most of it will probably go away by switching back to stock. I'll let people know how the experiment goes.

My tach isn't working yet as Bostig has yet to ship the Tach Mod. It's supposed to ship this week or next. It will be nice to get the tach going so I can have RPM's right in front of my face, and not just via the SCT device.

The oil level light flickers a lot, especially during right turns and going up steep hills. It's not a problem, but it's annoying. Bostig says it's a known issue, and that they are working on a circuit that will make it stop.

Finally, I'm getting some kind of a whirring, cavitating noise that seems like it is coming from the power steering pump. The system is bled, and fluid level is great. I only hear it while sitting still idling. It happens with engine hot or cold.

The guys at Bostig were great about helping me get the van ready last week. They were prompt, helpful and articulate when coming to my aid. Class act all the way.

More to come...
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Last edited by indytriple on Tue Mar 12, 2013 2:31 pm; edited 1 time in total
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Zero419
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PostPosted: Tue Mar 12, 2013 11:02 am    Post subject: Reply with quote

indytriple wrote:
Success!


I also have a whistle coming from somewhere when I shift from Park to Drive or Reverse. It only happens when the van has been running, and it is warm. As soon as I put it into Drive or Reverse I get a distinct, fairly loud whistle sound. It usually only lasts a few seconds until I start moving or give it some gas. I'm putting my money on the transmission, but I'd be eager to hear suggestions. Pump fluid starvation perhaps? The fluid level in the tranny is perfect.


The oil level light flickers a lot, especially during right turns and going up steep hills. It's not a problem, but it's annoying. Bostig says it's a known issue, and that they are working on a circuit that will make it stop.

Finally, I'm getting some kind of a whirring, cavitating noise that seems like it is coming from the power steering pump. The system is bled, and fluid level is great. I only hear it while sitting still idling. It happens with engine hot or cold.


More to come...


I get a whistle too. not sure what it is.

My PS pump made some noise for a while and then went away.

I complained about the oil light but never heard anything about a fix. let us know when it is in.
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PostPosted: Tue Mar 12, 2013 2:35 pm    Post subject: Reply with quote

Cool, I was getting scared when we didn't hear from you, thought you went off the deep end! Laughing

Ready for BBTB this year??

Is the power about the same as the EJ22?

Jeff
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