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Trashman
Samba Member
Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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 Posted: Fri May 31, 2019 9:10 am Post subject: Re: 1968 Deluxe Build |
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| metz wrote: |
| So cool. Engine build looks great. How much hp were you aiming at? |
Thanks! Your guess is as good as mine. I wasn't really considering hp when putting this together, I was really only concerned with low end torque so i can load the bus up with stuff and hit the mountain roads in 4th gear. And let me tell you, it now has no problem with that. I can accelerate in 4th up a hill with ease.
| asiab3 wrote: |
Are you saying the car levels itself left to right and front to back???
I just went from “I wanna but this guy a beer” to “I want to modify my bus now.”
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Hell yeah it does! Stop by Santa Cruz on your tour and we can chop your shit up on the street in front of my house  I'm moving on Tuesday so we can make a racket and not care if the neighbors like me lol.
| richparker wrote: |
| Engine looks great! I have a few questions. Who’s heads, what crank, what.l clutch, why didn’t you a stock fan housing and did you weld the fan to withstand that belt set up? |
Aircooled.net stock valve L3 heads that I opened up the chambers a bit and did a little bit removing the casting marks in the ports (they didn't need much at all). I went with stock valve heads because I wanted a low revving motor, not a screamer. With the smaller valves and ports, it keeps the air velocity higher down low which more or less equals more torque. This does in turn sacrifice cfm up high in the rpm's, but I'll really never be up there so it's a sacrifice that I was willing to make. For the crank I've got Kuhltek's 74mm 4340 chromoly crank. Reason for this choice being that they seem to make one of the only 4340 cranks in 74mm (everyone else seems to only make it in 4140). Didn't use the stock fan shroud for two reasons, one being I'm no longer running heat with that diesel heater that I still need to finish, and two being just being looks. And yes the fan is welded. When I got the bus, the fan spacing was off and it rubbed on the shroud and wore down the tabs on the fan veins so I had to weld it when I fixed the spacing issue.
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Bagged 1968 Neptune Blue "Deluxe" |
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richparker
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Joined: November 24, 2011
Posts: 6986
Location: Durango, CO
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| Posted: Fri May 31, 2019 7:53 am Post subject: Re: 1968 Deluxe Build |
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Engine looks great! I have a few questions. Who’s heads, what crank, what.l clutch, why didn’t you a stock fan housing and did you weld the fan to withstand that belt set up?
I remember when you set up the self leveling, pretty cool! Most of us just use lynx leveling blocks.
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’71 Westy build
Adventure thread
’65 Deluxe Build
’63 Deluxe Build |
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Manfreds78bay
Samba Member
Joined: February 27, 2009
Posts: 754
Location: PNW
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| Posted: Fri May 31, 2019 7:46 am Post subject: Re: 1968 Deluxe Build |
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Wow! Man...someone needs to snap this guy up and get him his own shop.
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1978 2.0L FI Campmobile
1982 AMC Eagle SX4 4.2L FI |
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bally
Samba Member
Joined: April 29, 2006
Posts: 1182
Location: Melbourne, Australia
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| Posted: Fri May 31, 2019 1:36 am Post subject: Re: 1968 Deluxe Build |
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| Epic update. Engine looks superb! Good luck getting it fully dialled in 😊 |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12728
Location: on a bike ride somewhere
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| Posted: Fri May 31, 2019 12:44 am Post subject: Re: 1968 Deluxe Build |
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Are you saying the car levels itself left to right and front to back???
I just went from “I wanna but this guy a beer” to “I want to modify my bus now.”
Nice work!
Robbie
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metz
Samba Member
Joined: March 31, 2005
Posts: 280
Location: Norway
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| Posted: Fri May 31, 2019 12:08 am Post subject: Re: 1968 Deluxe Build |
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So cool. Engine build looks great. How much hp were you aiming at?
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68 panel
64 ghia coupe |
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Trashman
Samba Member
Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu May 30, 2019 10:12 pm Post subject: Re: 1968 Deluxe Build |
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Here comes a long due update on the bus. As I was talking about before I have been working on a new engine for the bus. To be specific, I've been working on a 1968cc engine. The combination that makes this size is a 74mm stroker crank with 92mm pistons and cylinders. I went with 92mm thick wall cylinders because they are super thick, thicker than the stock ones, which are good for the heat that the extra load a bus creates for the engine compared to a bug. Everything in the rotating assembly was stack balanced and all of the reciprocating parts were balanced to each other. I used a stock weight flywheel (drilled for the 8-dowel crank). If you have any questions about any other components I used and why I used them, just shoot me a pm. Here's comes a massive photo dump of some of the process.
First thing I did with the new as41 case was to change the brazilian oil pickup for a german one (brazilian is grey and the german is the black one). I also ending up having to clearance the case for the larger stoke (not shown here).
Then I drilled and tapped for full flow and smoothed out the transition in the fitting since I was bored waiting for other parts.
Lifter grooves cut
Oil pump inlet rounded over to have a better path to full face of the gears
Breather box template
First mock up
Checking deck height determining the amount of shim needed (started with a positive deck)
Short block assembly
Long block assembly
Figuring out rocker geometry (solid rocker shafts used in final assembly btw)
Had a little mishap when my girlfriend was helping be transfer the engine from a stand to a dolly less than a foot away. Of course the mishap happened then and not when we carried it from my room to the backyard, even down stairs, lol 
Luckily I didn't have the pushrods installed!
Full flow lines fitment around mustache bar and headers
Oxygen sensor installed for dialing in the jetting
Almost done
The final product all installed!
Took the bus on its first excursion with the new engine this week. The girlfriend and I went camping in Butano State park again. I was doing tuning along the way and was able to get a lot dialed in. The way there was far from flawless but on the way back home there weren't really any issues, although there is still some room for improvement.
Somewhere on hwy 1
At the campsite. I bet your all stock westy camper can't level itself at the campsite can it? :2gunfire:
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Bagged 1968 Neptune Blue "Deluxe" |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12728
Location: on a bike ride somewhere
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| Posted: Thu Apr 11, 2019 7:46 pm Post subject: Re: 1968 Deluxe Build |
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Hahaha that’s good. I enjoy my Plug N Chug, probably my #1 used accessory besides my radio. Once you have the cup holders...........
Rkbbie
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu Apr 11, 2019 7:01 pm Post subject: Re: 1968 Deluxe Build |
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I was thinking the same thing. Contemplating if I would put it up front where I have the cb radio in the picture, or on top of the doghouse and have it mount using the top four bolts so I can take it on and off when I please.
I've never owned a car that has had cupholders so it seems like blasphemy to put cupholders in an old German vehicle (but chopping them up and bagging them doesn't). Interesting internal battle here lol
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Bagged 1968 Neptune Blue "Deluxe" |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12728
Location: on a bike ride somewhere
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| Posted: Thu Apr 11, 2019 4:36 pm Post subject: Re: 1968 Deluxe Build |
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With your fab skills, you could make a sick cup holder/stash spot for the front of that tunnel. 
Robbie
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notchboy
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Joined: April 27, 2002
Posts: 22463
Location: Escondido CA
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu Apr 11, 2019 1:02 pm Post subject: Re: 1968 Deluxe Build |
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I cut the mat and threw it on there. I think I can dig it.
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Bagged 1968 Neptune Blue "Deluxe" |
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu Apr 11, 2019 9:22 am Post subject: Re: 1968 Deluxe Build |
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HAHAHA. That might be the case lol. I could probably get them to stick together, just might not be pretty Good idea though, hadn't thought of that. If I can find a cheap mat at one of the two swap meets this weekend I might have to give it a try.
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Bagged 1968 Neptune Blue "Deluxe" |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12728
Location: on a bike ride somewhere
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| Posted: Thu Apr 11, 2019 9:17 am Post subject: Re: 1968 Deluxe Build |
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Looking good!
What about two mats discreetly melded together?
Or are you like me, and a total wizard in one medium but a chump in another? I can't do shit with metal but plastics do whatever I tell them to…
Robbie
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu Apr 11, 2019 9:04 am Post subject: Re: 1968 Deluxe Build |
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Got the doghouse for the beam finished up the other day. Still debating on whether or not to cut the walkthru mat to just cover the back 8 or so inches of the walkthru that's still flat, or to trim the sides of it so it would just lay on top of the doghouse but end where it starts curving back down in the front, or just to leave it alone and ditch the mat entirely.
The access panel on it works nice but I still need to put a bit of weather stripping around the perimeter of it.
Here it is, ba-da-bing ba-da-boom
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Bagged 1968 Neptune Blue "Deluxe" |
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panel
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Joined: December 02, 2001
Posts: 1091
Location: Victoria B.C. Canada
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Thu Apr 04, 2019 12:02 pm Post subject: Re: 1968 Deluxe Build |
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| panel wrote: |
| Trashman .........can you post a better view of your outer tie rod ends and what you did there? Is it all custom or have you purchased parts etc ? |
I don't have any pictures of the ends but if I get the time to take any I'll pm you. The ends are these QA1 high-misalignment rod ends that I got off of summit. https://www.summitracing.com/parts/QA1-PCYMR8T . The spindles were drilled out and sleeved to be a perfect fit for the 1/2" bolt.
| notchboy wrote: |
| Its just going under the buddy seat right? |
The heater is going under the buddy seat and the fuel tank is going in the engine compartment opposite the battery. I am going to duct the hot air under the bus so that it comes out of the stock vents up front. My main priority with the heater was defogging/defrosting the windshield. The initial 90* after the ducting goes under the floor will be the trickiest because I have to keep it under the frame rails as well as route around all of the cable tubes that run in that vicinity.
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Bagged 1968 Neptune Blue "Deluxe" |
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notchboy
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panel
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Joined: December 02, 2001
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Location: Victoria B.C. Canada
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| Posted: Tue Apr 02, 2019 11:14 am Post subject: Re: 1968 Deluxe Build |
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Trashman .........can you post a better view of your outer tie rod ends and what you did there? Is it all custom or have you purchased parts etc ?
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Trashman
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Joined: May 18, 2016
Posts: 280
Location: Santa Cruz, CA
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| Posted: Tue Apr 02, 2019 11:01 am Post subject: Re: 1968 Deluxe Build |
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Hahaha I know. I put in a little work on the fuel tank for it the other day. Our winter in Santa Cruz has been rainy, just not very cold so the incentive hasn't been too high to finish it. The ducting is going to be tough since I have to make some custom elbows out of sheet metal.
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