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1.8T DIY Conversion Stephans Auto Haus Kit 1985 Westy
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ThankYouJerry
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PostPosted: Fri Nov 14, 2014 8:09 pm    Post subject: Reply with quote

kbeefy wrote:
Watching to see how awesome the 1.8t swap is....


Kinda "old news" at this point. The 1.8T has more than proven itself when it comes to great Vanagon engine conversions. The only issue with the 1.8T conversion is (if you have an auto trans) which R&P?
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Bills85Westy
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PostPosted: Fri Nov 14, 2014 8:11 pm    Post subject: Reply with quote

zeohsix wrote:
I noticed one other item. You say your getting a automatic donor motor......I know my 2004 Jetta AWP donor motor was an auto transmission.....did Stephan change his kit? My heater hard lines didn't have the nipples in the right place for the SAH hose assembly that came in the kit. I had to locate a heater hose hard line from a manual transmission AWP motor to make the parts work. Do yourself a favor! Don't order a hard line from Hans Auto parts, they are very poor quality. Stephan should really establish a users forum for people deciding yo do a DIY 1.8T swap as there are some details not completely covered by the present manual and a forum would be a much more open source to ask for assistance in getting the swap completed.


Hi,

Actually, Stephan and I spoke about this. The heater hard lines need to be changed as you note. He said that he should be able to sell me a set of lines.

Completely agree on the forum idea. This is exactly why I posted here. This is great information & a way for me to connect with other Sambanistas who have performed the swap or have a 1.8 conversion.

Thanks again.
Bill
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Bills85Westy
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PostPosted: Fri Nov 14, 2014 8:22 pm    Post subject: Reply with quote

nacradriver wrote:
Bill....

+1 on posting this... This is the conversion I am leaning towards...

Would you mind sharing what your donor engine & components cost?

Good luck on your conversion....


I purchased the engine & swap components from Austin Imports in Austin Texas. The total cost including shipping delivered to my shop (construction company with a forklift) was $2,500.

I am expecting to spend another $500-$1,000 getting the engine ready for installation plus incidentals. This is exclusive of SAH kit plus options, plus tax.

Here is the FB page for Austin Imports:
https://www.facebook.com/pages/Austin-Imports/229092597256417
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85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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nacradriver
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PostPosted: Sat Nov 15, 2014 5:42 pm    Post subject: Reply with quote

Bills85Westy wrote:
nacradriver wrote:
Bill....

+1 on posting this... This is the conversion I am leaning towards...

Would you mind sharing what your donor engine & components cost?

Good luck on your conversion....


I purchased the engine & swap components from Austin Imports in Austin Texas. The total cost including shipping delivered to my shop (construction company with a forklift) was $2,500.

I am expecting to spend another $500-$1,000 getting the engine ready for installation plus incidentals. This is exclusive of SAH kit plus options, plus tax.

Here is the FB page for Austin Imports:
https://www.facebook.com/pages/Austin-Imports/229092597256417


Yes.... I see these guys advertised on Flea Bay all the time....
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Bills85Westy
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PostPosted: Sat Nov 15, 2014 6:18 pm    Post subject: Reply with quote

nacradriver wrote:
Bills85Westy wrote:
nacradriver wrote:
Bill....

+1 on posting this... This is the conversion I am leaning towards...

Would you mind sharing what your donor engine & components cost?

Good luck on your conversion....


I purchased the engine & swap components from Austin Imports in Austin Texas. The total cost including shipping delivered to my shop (construction company with a forklift) was $2,500.

I am expecting to spend another $500-$1,000 getting the engine ready for installation plus incidentals. This is exclusive of SAH kit plus options, plus tax.

Here is the FB page for Austin Imports:
https://www.facebook.com/pages/Austin-Imports/229092597256417


Yes.... I see these guys advertised on Flea Bay all the time....


Vladi at Austin Imports told me that this is the 27th package that he's put together for the 1.8T Vanagon swap. Not sure if these were all for Stephan or just in general.
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85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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furrylittleotter
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PostPosted: Sat Nov 15, 2014 6:43 pm    Post subject: Reply with quote

Bills85Westy wrote:

The install manual is 185 pages.

Honestly, I am looking forward to the learning experience and challenge.
.


Sounds good going into it, like you have all your bases covered. Will be nice not having to strip a donor, that seems like a bargain if it included shipping...quite a challenge ahead. Hope all goes well.

What a giant manual.

Neil2
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kbeefy
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PostPosted: Sat Nov 15, 2014 7:54 pm    Post subject: Reply with quote

ThankYouJerry wrote:
kbeefy wrote:
Watching to see how awesome the 1.8t swap is....


Kinda "old news" at this point.


Yeah I know. Just want to watch a detailed account of the install.
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Bills85Westy
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PostPosted: Tue Nov 18, 2014 8:50 pm    Post subject: Reply with quote

The motor & conversion parts arrived today from Austin Imports. They shipped last Friday, scheduled to arrive tomorrow & arrived today. I am very impressed with the packing & crate.

I had a few minutes at the end of business today to open the crate & take a look. All is as promised.

On Friday, I am taking the motor over to a friend, Andrew, who owns Napa Autowerke (here in Napa) for a diagnostic review of the motor & to put together a game plan for general service, repairs & rebuild as necessary.

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.


I'm also moving some other projects (1959 Austin Gipsy rebuild) around in the shop to make room for the Westy. Hopefully will be getting started setting up the shop for this project this weekend!

Bill
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85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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BlueGrasser
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PostPosted: Tue Nov 18, 2014 10:27 pm    Post subject: Reply with quote

Popcorn
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'88MoneyPit
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PostPosted: Tue Nov 18, 2014 11:30 pm    Post subject: Reply with quote

I went for the ecu anti- theft. Worth every penny

S
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Bills85Westy
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PostPosted: Thu Dec 11, 2014 8:07 pm    Post subject: Reply with quote

Okay, time for an update...........

So I got the 1.8 mounted on an engine stand for a general cleanup and service. I was originally going to have a local german mechanic (and personal friend) perform the service, but decided that based on the amount of cleanup that it would be easier to do in my shop.

I went last Friday to pick up the conversion kit from Stephan. He spent about an hour with me. We loaded everything into my truck, reviewed everything included & then just talked generally. He said repeatedly to "keep me in the loop" & gave me his cell number. I haven't used it yet, but i'm sure I will. Here is how everything came:
All the miscellaneous parts boxed up:
Image may have been reduced in size. Click image to view fullscreen.


The new engine carrier:
Image may have been reduced in size. Click image to view fullscreen.


The new raised deck lid:
Image may have been reduced in size. Click image to view fullscreen.


The new 2.5" stainless steel exhaust Cool
(I'm pretty excited about this improvement which is good for a chunk of horsepower!
Image may have been reduced in size. Click image to view fullscreen.


I went through and inventoried everything.......
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.


Each part is numbered with a description that matches the installation manual.
Image may have been reduced in size. Click image to view fullscreen.


I then unpackaged all of the parts and got them sorted on a rack in the garage.
Image may have been reduced in size. Click image to view fullscreen.


This past Saturday, I started to cleanup and service the 1.8. I suspect that for me, this is what is going to take the most time. Clean, inspect, add parts to a list, clean some more. Clean even more, etc. etc. etc.

Items that I am doing to the 97,000 2005 motor that are not included in the conversion:
- New timing belt & tensioner
- New water pump (metal impeller)
- New oil pan pick up tube & o-ring
- New coil pack connector (on Cylinder #2 (broken tab))
- New valve cover gasket
- New oil pan gasket (this is an RTV sealant as stock)

I ordered these parts through WorldPac from my mechanic friend. He was also able to advise on the quality of various parts. E.g. water pump with metal vs. plastic impeller.

It's taken me about 5 days to completely clean the top end, the turbo side of the engine, the multi-port water connection at the back of the motor & strip the intake side of the motor. I have been installing Stephen's conversion parts as I get to that part of the motor.
Image may have been reduced in size. Click image to view fullscreen.

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


Generally, i am going pretty slow at this point because A. I am learning the 1.8 with the help of the internet; identifying each part & it's condition & B. I really need to understand the "why" of each part in the conversion. At this point, there is still a lot of uncertainty about how each part is supposed to fit or finally connect. After some time researching I am getting comfortable with each step.

My guess is that I will have the motor mostly prepped by the end of the weekend and will have started on the Vanagon which I am much more comfortable with.

My goal currently is to be complete with the conversion by mid-January. I have taken some time off around Christmas so will be able to focus some time in the shop.

Lastly, I took advantage of the Thanksgiving GoWesty sale & also have a "Big Brake" kit to install! Very Happy

I hope to post another update this weekend.
Bill
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85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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Jake de Villiers
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PostPosted: Thu Dec 11, 2014 8:12 pm    Post subject: Reply with quote

Nice comprehensive kit! I was privileged to meet Stephan when we were down at Grass Valley.

He is a really good guy. Smile
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'88MoneyPit
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PostPosted: Thu Dec 11, 2014 11:25 pm    Post subject: Reply with quote

If you want specific pics of areas of the install let me know.

S
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Bills85Westy
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PostPosted: Fri Dec 12, 2014 12:11 am    Post subject: Reply with quote

'88MoneyPit wrote:
If you want specific pics of areas of the install let me know.

S


Great! Thanks.
Bill
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SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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danfromsyr
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PostPosted: Fri Dec 12, 2014 7:38 am    Post subject: Reply with quote

looking good and laying out for some real progress.

but man that's a NICE garage cabinet there.. safe and all.

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djsixbillion
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PostPosted: Fri Dec 12, 2014 10:42 am    Post subject: Reply with quote

Good stuff! I just finished up my SAH kit install a few weeks ago and am very pleased with the outcome. Let me know if I can help with any issues that come up along the way. I'm fairly local (Sacramento) and have friends near Napa.

Wish I would have known about that anti-theft option when I ordered the kit. I'll have to ask Stephan if it's possible to add after the fact...
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Bills85Westy
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PostPosted: Fri Dec 12, 2014 10:47 am    Post subject: Reply with quote

djsixbillion wrote:
Good stuff! I just finished up my SAH kit install a few weeks ago and am very pleased with the outcome. Let me know if I can help with any issues that come up along the way. I'm fairly local (Sacramento) and have friends near Napa.

Wish I would have known about that anti-theft option when I ordered the kit. I'll have to ask Stephan if it's possible to add after the fact...


I need to check in with him on this as a matter of fact. It is listed on the order, but no mention that I can see in the manual or in parts that he has supplied. I'll keep you posted. This might be a completely separate component that can be added. Not sure.

Bill
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85 Westfalia Syncro (conversion)
SAH 1.8T Conversion - 2005 AWP 1.8
Front and rear lockers and decoupler
Engine Conversion Thread: http://www.thesamba.com/vw/forum/viewtopic.php?t=612144&highlight=
85 Doka L345 Grey - 1.9L
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'88MoneyPit
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PostPosted: Fri Dec 12, 2014 11:30 pm    Post subject: Reply with quote

You need cruise control for the anti theft. You enter the code to activate/deactivate through the cruise control buttons. If you have cruise then you need to get the computer reprogrammed to anti theft.
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PostPosted: Fri Dec 12, 2014 11:53 pm    Post subject: Reply with quote

'88MoneyPit wrote:
You need cruise control for the anti theft. You enter the code to activate/deactivate through the cruise control buttons. If you have cruise then you need to get the computer reprogrammed to anti theft.


you need the cruise control and the ECU chip

http://www.h2ovanagon.com/H2oVanagonConversions/18TOptionalAddons.aspx
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PostPosted: Sat Dec 13, 2014 12:08 am    Post subject: Reply with quote

You need... only money Razz Laughing
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