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Installing Rostra Cruise Control into 1986 2.1 Automatic
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djkeev
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PostPosted: Wed Jul 27, 2016 3:14 pm    Post subject: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

EDIT: This was attempt #1 this attempt ended in frustration and failure for me. In the end I pulled the system out!

Being a candidate for torture, I'm trying it again. I made a new thread for attempt #2.......

https://www.thesamba.com/vw/forum/viewtopic.php?p=9610221#9610221

***********************

In this linked thread I Asked about what cruise control units are available for units that came without one.

http://www.thesamba.com/vw/forum/viewtopic.php?t=659845

From discussions I decided to get the Rostra 250-1223 universal unit.

While I await its arrival I am doing some basic preparation work.

Rather than cut into my factory brake harness and tap the brake light, I am adding a 2nd mechanical brake light switch operated by the brake pedal.

I plan on making a bracket to fit to the right of the steering column utilizing these two factory holes you see in the photo to mount the brake light switch above the pedal arm......

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


Dave
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DwarfVader
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PostPosted: Wed Jul 27, 2016 3:17 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Popcorn This promises to be an informative and interesting thread...
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PostPosted: Wed Jul 27, 2016 3:21 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

DwarfVader wrote:
Popcorn This promises to be an informative and interesting thread...


Maybe in a month or so you can actually SEE how it came out! Wink

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PostPosted: Thu Jul 28, 2016 3:42 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

To make the brake light switch bracket, I've got a length of Aluminum flat stock and also some steel.
I'm more comfortable working/bending steel so that will probably be my choice.

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


Here's my brake light switch. This is a switch from a 60’s-80's Chevy or Dodge.
A basic on/off contact switch.
The threaded barrel is a must have in order to adjust it properly once installed.

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


To power the whole assembly I picked up this piggy back fuse unit.
I don't plan to double up on an existing feed but rather I'll utilize a vacant fuse spot but not get into using the special plugs on the back of the fuse panel....

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


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PostPosted: Thu Jul 28, 2016 3:47 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

The magnetic pickup came today. Fairly basic technology.

They sent a zip tie to hold the magnets in place, I'll use that plus some epoxy to keep them from moving.

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


The pickup coil comes with 8' 3" of wire. That is about the Van's wheel base.

I think I'll be adding a few feet on but I've not yet seen the Rostra harness, I Don't know how long the pigtail is for the VSS input.

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


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


Now, if I can get work to ease up a tad, I can install this stuff!

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PostPosted: Thu Jul 28, 2016 11:13 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

One of my future projects. I plan on buying that same unit. Maybe you will inspire me to pull the trigger. Keep the tutorial coming.
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PostPosted: Fri Jul 29, 2016 11:38 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Making the brake light switch bracket.

3" x 3" x 1/8" steel, edges filed smooth....

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


Because of the steering shaft being "off center" I need to provide clearance so I can utilize both factory holes above the brake pedal to mount the bracket....

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


Cuts made, filed smooth and holes drilled for mounting the bracket.....

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


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PostPosted: Fri Jul 29, 2016 12:14 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

The bracket mounts on the Air box/crash beam pointing straight down.
The bracket needs to be bent to the angle of the brake pedal arm at rest.

I scribed a line at the bend point.....

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


Clamped it into the vise .....

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


And bent it cold using a 12 oz ball peen hammer.
It was a trial and error thing until it fit.

I located the brake arm and drilled a 1/2" hole for the switch.....

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


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PostPosted: Fri Jul 29, 2016 12:18 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

I installed the switch on the bench.....

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


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


And mounted it in place. The terminals are close to the steering system but they clear just fine! I did grind off some sharp factory corners on the steering shaft as you can see in the photo.

I adjusted the switch and tightened the two nuts. All is good!

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


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PostPosted: Fri Jul 29, 2016 1:51 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

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


Considering how many hydraulic brake light switches I have replaced through the years that is a pretty nice mod right there even if one is not installing cruise control.

I did a similar switch on one of my other cars that uses a stock hydraulic switch -

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


The switch I used came from Amazon -

https://www.amazon.com/Standard-Motor-Products-SLS...dard+volvo

On the van my cruise cut-out is connected to the brake light itself - only advantage in that is that I can tell when the hydraulic brake light switch has failed because the cruise cannot be shut down by applying the brakes (yikes). I like your approach better.
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PostPosted: Fri Jul 29, 2016 3:12 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Interesting.......... I found fuse #5 on my 86 to be vacant and powered with the key on.

I slipped in my Piggyback which fit only because fuse #6 is also vacant! That gave space for the 90* fuse mount.

Anyway I thought "What is fuse #5 for I wonder."
Opened up the Bentley and fuse #5 is the fuel pump?!??
My fuel pump has power from the black box in the engine compartment.

🤔

Edit: just looked at my owners manual...... Fuse #5 empty

Bentley.....
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Owners manual

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PostPosted: Sat Jul 30, 2016 6:30 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Whoo Hoo!!

The Rostra Universal kit is scheduled to arrive today!
I can work on it tomorrow!!!
🤗

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PostPosted: Sat Jul 30, 2016 6:39 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

djkeev wrote:
Whoo Hoo!!

The Rostra Universal kit is scheduled to arrive today!
I can work on it tomorrow!!!
🤗

Dave


I think you'll like it! I'm going to make a final suggestion to go with the wireless switch. Using it allows me to adjust the CC w/out moving my hand from the steering wheel. It makes a convenience even more convenient and I've had years of reliable experience with it in two cars.

That said, it's your van and I'm sure you'll do what's best for it. Very Happy

Enjoy!
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PostPosted: Sun Jul 31, 2016 11:27 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Here is the Rostra unit.......

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


The wires are amazingly generous in length!

The harness stretches from the front bumper to past the rear wheels in this photo!
The longest wires are the blue and the grey ones formthe VSS and the Tach hookup.

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


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PostPosted: Sun Jul 31, 2016 11:30 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Jim, thanks for the RF control recommendation but my die is already cast with the wired dash unit. The wired unit will be here Monday.

GoWesty suggests mounting it under the 4 way hazard switch but I have installed a switch there that I use to use to cut off my A/C compressor which allows me to use the rear A/C fans to circulate air without cooling.

Anyway, I plan to mount the wired switch on the left side of the steering column just forward of the Turn Signal switch.
It won't be easy to see the buttons while driving, but there's only two, it can't be too difficult to operate blind.

This grainy photo shows the intended location using green tape.....

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


I also see that GoWesty has their Speedo mounted VSS back in stock.

I'm sticking with my magnets, in part I have them already, second because my speedo needle jumps so I have concerns about having a jumpy VSS reading as well.

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PostPosted: Sun Jul 31, 2016 11:49 am    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

That looks like a good spot and possibly a bit easier to get to than on the dash.

I've posted this pic elsewhere, but you can see that the buttons aren't visible to the me but I have no problem knowing exactly where they are. For some reason, I think Ford once put buttons on the back of steering wheels (I'm not certain about that though).


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

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PostPosted: Sun Jul 31, 2016 1:39 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Interesting comment about the jumpy needle, my Syncro needle is jumpy and it throws off my Factory cruise as well. Sometimes to the point that it will not engage. Good call on the magnets, I have used them on previous C/C installs and they work great and really do not shift around.
Why not just use one of the two brake light switches as your cut off for the cruise? I can appreciate why VW uses the 2 switches, but most people who own and maintain their Vanagons don't let their brakes not work.
I have never seen one of those fuse taps, a very simple way to get power and not make a mess of your harness.

Stacy
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PostPosted: Sun Jul 31, 2016 4:23 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

djkeev wrote:
GoWesty suggests mounting it under the 4 way hazard switch but I have installed a switch there that I use to use to cut off my A/C compressor which allows me to use the rear A/C fans to circulate air without cooling.


that spot on the instrument cluster is really nice. I had my Rostra controller there before GW started carrying the unit.

Why not just turn the temp all the way warm while having the fan on?
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PostPosted: Sun Jul 31, 2016 4:59 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

16CV, Stacy....
I'm using the add on mechanical brake light switch so I don't cut into the factory VW wiring harness. Though I Imagine I can just pull the terminals and piggy back off of them without cutting wires on one of the hydraulic switches.
I may use both, add redundancy disconnect into the system.
Thanks for verifying what I suspected about the jumpy speedo and accurate cruise!

Vanis13, the switch probides a solid shut off of the compressor, be it pulling a long hill or whatever. I imagine the thermostat would work to shut it off to a point depending upon ambiant temperature?

Anyway..........

Step #1
Cut threads on the actuator cable.

Rostra sends some hardware for the cable, two nuts and a "P" ring. These three items are cut with 1/4-20 threads.......
Instructions say to run the nut over the plastic cable to make threads but that seemed laborious, I used a die that tended to mash in threads instead of cut threads.

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


I also dropped the spare tire carrier and pulled off the spare to gain access to the throttle cable linkage under the pedal.

It has a plastic debris cover over the linkage held on with three short sheet metal screws.......

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


Remove the screws, the cover slides back on the accelerator cable exposing the linkage..... (White plastic pipe is the accelerator cable)......

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


I Will be fastening the actuator cable SHEATHING to the accelerator pedal attachment point using the 1/4-20 thread "P" clamp. The threads will give me adjustment.

Just an FYI....... I totally took this mounting to the throttle idea from GoWesty.......

Give credit where credit is due........ I'm not that smart!

Dave
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PostPosted: Sun Jul 31, 2016 5:12 pm    Post subject: Re: Installing Rostra Cruise Control into 1986 2.1 Automatic Reply with quote

Where to put my actuator?

GoWesty puts it on the air duct/crash beam behind the glove box and feeds the actuator cable down through the heater hose grommet to connect with the accelerator pedal.

My plans are for an A/C evaporator behind the glove box so this is not a potential location for me.
For most of you, its a perfect spot!

Hmmm...... Lots of space under the drivers seat.........

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


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


Mounting it here gives a straight shot to the accelerator pedal! That's nice!

But Wait!
When you fasten the mounting bracket, it raises the actuator up which creates interference with the seat bottom!

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


This is no good.....

What about in the left battery box?
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