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TDI into '78 Bus Build Thread
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Paul Hoegemeyer
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PostPosted: Tue Feb 27, 2018 11:25 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Thanks for the information. 2600 at 70 mph is that what you were shooting for? How is it working for you? Did you have taller tires before you went to
the Grabbers? Did they make a difference? Sorry for so many Questions.
Thanks
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vwwestyman
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PostPosted: Tue Feb 27, 2018 3:18 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Paul Hoegemeyer wrote:
Thanks for the information. 2600 at 70 mph is that what you were shooting for? How is it working for you? Did you have taller tires before you went to
the Grabbers? Did they make a difference? Sorry for so many Questions.
Thanks


Those numbers were just an example.

For the most part, driving around in flat-ish Kansas my gearing is pretty decent. When I was in Colorado last summer, there were times I kind of wished that the RPMs were a little higher.

The Grabbers are nearly the same diameter as the original tires I had on the New Beetle rims. I mostly wanted the off-roadish tires and also liked having a little less rubber on the contact patch. The transmission gearing was selected with this tire size in mind.

That said, I did a short experiment towards the end of last summer by putting stock size wheels and tires on to see if there were any appreciable difference noted. The RPMs dropped in 4th gear by about 100 but things like engine heat, intake heat, noise, etc did not show appreciable differences.
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Dave Cook

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Paul Hoegemeyer
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PostPosted: Thu Mar 22, 2018 7:29 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Can you measure your ground clearance at the oil pan when you get a chance?
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PostPosted: Thu Mar 22, 2018 8:36 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Sure, I don't mind doing that! I'll do my best to remember tonight. If you don't see an answer in a day or two, that simply means I forgot. (Took a brand new kiddo the other day, and the first few days are always kinda crazy!) So feel free to "ping" me again.
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PostPosted: Fri Mar 23, 2018 8:07 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Ok, oil pan clearance is 9.5 inches, the lowest part of the muffler is right at 9 inches. The oil pan is more or less right on the same plane as the carrier bar. At some point I will probably build some kind of skid plate to provide a bit more protection for the oil pan because it is cast aluminum and therefore a little more prone to damage from a rock strike than steel, which would just dent in most cases. That said, I did the Colorado Off-Road trip last summer and felt that it was just fine.

The radiator scoop body is 8 inches, the very front lip of it is 7.75 inches.

I am very sure that the torsion bars are now set at the factory specs, or ever so slightly higher.
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Paul Hoegemeyer
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PostPosted: Fri Mar 23, 2018 8:38 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Thank you
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vwwestyman
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PostPosted: Fri Apr 06, 2018 2:12 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Super simple, quick and easy improvement this afternoon.

I was really tired of the worn out mirrors and lack of visibility. The silvering on the backside was badly damaged, and the glass had been reattached with silicone by a PO. So the original mirrors were looking shabby at best.

Did a head replacement on a Vanagon last week, so I spent some of the payment on new Brazilian Bay mirrors from Bus Depot.

Even though some may not love the looks, I think it fits with the vibe of this Bus, and the visibility is significantly improved.

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


Jackson approves.

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PostPosted: Sat Apr 07, 2018 10:11 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Don’t forget to snug the Phillips screws down to keep em from wiggling loose. Often they come loose new. Look under the rectangle of the mirror, there’s two per mirror and you’ll have to turn the glass around to get to both.
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vwwestyman
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PostPosted: Sun Apr 08, 2018 7:03 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

I am not smelling what you're stepping in. Are these screws in the bracket part, or the mirror part?
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PostPosted: Sun Apr 08, 2018 7:06 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

vwwestyman wrote:
I am not smelling what you're stepping in. Are these screws in the bracket part, or the mirror part?


Mirror part.

The mirror pivots on a ball and the screws tighten the socket the ball pivots in. The screws at directly above said ball in he bottom edge of the mirror.
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PostPosted: Mon Apr 30, 2018 8:51 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Just won a bid on ebay for a reconditioned Espar D2 diesel heater. About half the price of a new one, and included a bunch of new install parts. Even though I won't need it (HOPEFULLY!) for some time, I'm excited about it. That has been on my list for some time now.
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Dave Cook

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vwwestyman
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PostPosted: Thu May 24, 2018 9:02 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

vwwestyman wrote:
Just won a bid on ebay for a reconditioned Espar D2 diesel heater. About half the price of a new one, and included a bunch of new install parts. Even though I won't need it (HOPEFULLY!) for some time, I'm excited about it. That has been on my list for some time now.


Install thread for this project:
https://www.thesamba.com/vw/forum/viewtopic.php?t=699008
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Dave Cook

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PostPosted: Thu May 24, 2018 9:12 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Besides working on the Espar project, today I did a little modification to the fridge circuit. Ever since starting the conversion I haven't had the second battery, so the fridge hasn't worked on battery power for a long time. It does still work with 120v power.

No real matter, though, because I never really used it as a fridge, more as a cooler than anything. We all know they weren't that super efficient when new.

However, I had already set up an alternator-controlled circuit in the bus, for things like the intercooler pump to only run when the engine is running.

So I ran a wire from another of those fuses (which I had intentionally left for tripping a relay for the second battery if I ever installed it) straight to the fridge's battery connection.

This means that for now, when I'm driving, I can run the fridge. My thought is that I'll still use it as a cooler (cooling provided by frozen water bottles primarily), and running the fridge while driving will just go a little bit further to helping the ice in the bottles last a while longer. I suppose if it doesn't actually add that much to the cooling of the fridge (it'll certainly depend on the distance/time driving) at least this literally cost me zero and works.

I do have plans to put a new battery tray in and reinstall the battery in the engine compartment in the nearish future. I don't know if I'll decide I want the rear-seat space back, or eventually install an auxiliary battery there.
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PostPosted: Mon May 28, 2018 9:24 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

I took the Bus from Manhattan to Table Rock Lake, MO this weekend. My aunt and uncle have a cabin there so I met up with the family there. First time there, it was great! Unfortunately they're going to sell the place. Dang it!

I left a day early and camped Friday night at a little state park along the way. Because of the Memorial Day weekend, every single spot was taken, so I just decided to sleep in the parking lot for the marina.

I was woke up by a park ranger a couple hours later, saying that I wasn't supposed to sleep there and needed to move to the one open spot on the other side of the lake, and he'd escort me over there.

I advised I'd be happy to move, but I'd had a couple beers... So he said to just stay there and not to do it again.

Stopped at the grocery store on the way to the cabin to pick up all the essentials:

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


Because they are selling the cabin, they decided to give me the canoes they'd purchased for use there. So we put one on top of the Bus and I hauled it home. (I'll retrieve the other later.)

Though I have had some issues along the way, this pic illustrates why I did the conversion. There is a canoe on top of the Bus, but the entire way home I had the cruise control set at 75 MPH. It was about 90 degrees out, but the engine ran just fine at about 200 degrees. Slightly warmer than I'd prefer, but well within reason. On the way down, with no canoe up there, I ran about 10 degrees cooler.

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


Anyway, the trip went just fine. At some point I'm going to need to think about reinstalling air conditioning! (It had AC years ago.)
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PostPosted: Mon Jun 04, 2018 9:55 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Ever since I got this Bus way back in 2002, the battery tray has been rusted out. Up until I removed the aircooled motor, the battery was "supported" by a chunk of plywood "installed" by the PO.

When I did the motor swap, I moved the battery to under the seat.

Recently I decided that I either wanted that space back, or maybe would rather use the space for reinstalling a house battery. That meant putting the battery back in the engine compartment.

So I bought one of the repro battery trays, trimmed it to fit, and painted it. I then wire wheeled what was left of the old tray, acid treated it, and painted it.

Then I used some panel adhesive epoxy to hold the new tray in to the "flanges" that is the remnants of the old tray.

After changing some wiring around, I now have more space under the back seat!

Hopefully I can get back to the Espar heater install/setup and finish up that project. Been waiting for a few parts to arrive.
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PostPosted: Mon Sep 03, 2018 11:16 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

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Started a couple improvement projects this weekend.

I pulled the motor to greatly improve access.

I've got a couple camping trips planned in October, so I wanted to make a few things a little nicer for them.

I'm planning to (attempt to) improve the sound control from the engine. Plans include pulling the shift rod to see why it rattles so damn much-I replaced the parts when I put the motor in several years ago but it certainly feels and sounds like somewhere it is rattling against the tube or something.

Also going to add some ReckHorn mat (like dynamat) in the fuel tank area as well as some rock wool insulation to absorb some sound. I also bought a product that is supposed to block and absorb sound, which I will install above and in front of the transmission, and if I have leftovers I'll also install it in the engine area. Prior to install of that mat, I will treat the area and paint it with the Master Coat paint.

Additionally, I ordered a nice-looking relay/fuse box that I'll install in the engine compartment to clean up things with that. They are kind of a mess, and I had a brief issue this summer with a wire coming loose and causing the engine to lose power. So that will all be improved.

Finally, I plan to improve and clean up my water to air intercooler system. Primarily adding a small tank which should make it significantly easier to fill the system as compared to the puny in-line filler I have been dealing with. I'm also hoping that I can mount the intercooler in such a way that I can once-again free up space for a second battery to go back there again. I also have the original radiator I bought for this engine install if you recall way back when. I think with a little welding, some ports can be added to allow me to repurpose that radiator to work with the intercooler.
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PostPosted: Tue Sep 04, 2018 11:35 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

The sound deadening that Skills did for us made a significant difference in noise levels. In fact, at times, we wish it was more Wink Something to drown out the boys! It's nice to be able to hear each other more easily now.

We have some gear shift rod chatter too! I know Skills massaged the floor at one point to provide a bit more room for the rod, but we do get chatter, especially in 3rd gear.

Good luck with the project!
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PostPosted: Tue Sep 04, 2018 1:41 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

I sure hope it works! I rehung the exhaust from the engine rather than the body prior to pulling it but that didn't make much difference as far as I could tell. (I had been told that some of the noise I was getting may have been exhaust vibrations reverberating through the frame.)

It did make pulling the engine a little easier-since the exhaust now comes out as a part of the whole package rather than having to be partially disassembled.
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Dave Cook

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PostPosted: Tue Sep 04, 2018 5:18 pm    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

Well it has been really rainy the past couple days, enough to circumvent the effectiveness of the awning I put up. That plus I'm still waiting for lots of parts to arrive. So I haven't made a lot of progress yet on the actual project at hand.

But, I did get a chance to fix a major annoyance I've had since starting this thing.

The oil filler was under the package tray, and therfore inaccessible with the engine installed!

So I added a second filler that will be under the opening when the hatch is removed.

I cut up a spare valve cover I had to get the part the cap attaches to, and used a piece of scrap exhaust pipe I had leftover.

Cut and shaped the pipe to fit the profile of the valve cover, drilled 3 holes in the cover, welded, painted, wala!


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


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


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


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


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


In case you were wondering how I filled it before, I usually just used a narrow funnel in the dipstick tube. This worked but as you can imagine was annoying and took a while.
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Dave Cook

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PostPosted: Wed Sep 05, 2018 5:27 am    Post subject: Re: TDI into '78 Bus Build Thread Reply with quote

With the shifter buzzing/rattling, I've long suspected that part of the problem may be too soft of motor mounts and have kicked around the idea of trying to find another type of mount that would fit the space.

Well with googling around, I've run across the idea of filling the voids in the mounts with various compounds. The popular one seems to be 3M Window Weld. Some have reported a marked increase in vibraitons, others reported minimal. All reported less engine movement, tighter shifters, etc. I suspect the main difference is the particular vehicle/application.

I've also seen mentions of other things like chunks of rubber hose to stuff into the voids.

So my original mounts do collapse pretty quickly. They seem to be the same as stock on a VW Fox.

I've got a spare set, so I want to fill them while the engine is down and see what that does. I'm thinking something that is still a little squishy to mitigate potential vibrations, but will still prevent it from collapsing as much.

I'm all ears for suggestions on what to use. I'm currently thinking silicone sealant.

You can see the partially collapsed mount in this pic; it isn't as compressed as when the engine was installed because the full weight of the engine isn't on the mount.

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


Here is what a new mount looks like. I bought an extra pair from Mexico before I found out they were the same as VW Fox mounts. I guess now this counts as a NOS part! ha ha

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

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