85 Westy refresh. Plenty of questions to follow. Bulli Klinik

[Bulli Klinik]

Hello friends. I recently picked up a 85 Westy. The Bus has spent a bit of time here on the Samba forum with the previous owner:
https://www.thesamba.com/vw/forum/viewtopic.php?t=684598

I've been a Bus guy since the mid 80's and have owned everything from a 58 Westy to a 87 Westy Syncro. My current driver is a 70 but I'm getting to a point where I'd like to get into something a bit more modern with better heat. Looking forward to sharing the project and getting some advice. Current plans call for a freshened up motor, a bit of rust repair with the intention of a full paint job in the near future and a general cleaning and personalizing of the Van...Did I just say Van?

As arrived. Rick, the previous owner, did a great job of packing everything. The project was just a bit too much for him right now but he plans on getting back into a Bus in the near future.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

From speaking with Rick and checking the thread, I knew the heads were cooked on the motor that came with the Bus. I have a friend who recently installed a Vanistan motor in his low mile (88K) Westy. As a result, he had a good running 1.9 for sale. We struck up a deal and I brought it to the shop. He even had it in a crate! As a bonus, he threw in a perfectly good, stock exhaust. Seeing the rust on the Bus, I had a feeling I would need a new exhaust so this worked out perfectly.

I loaded up my trusty camper and picked up the booty:

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

The previous owner mentioned that he had the head/cylinder gaskets replaced prior to removing the motor. I was hoping for a plug and play moment, buy anyone who's worked on this stuff long enough knows that's never the case.

One it got the motor up on the stand I noticed that the rear mounting stud was bent and something had pushed up into the pushrod tubes. Looks like the heads will have to come off anyway.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I forgot to take photos in the heat of the moment of the tear-down, but was pleased to find only very lightly scuffed cylinders and a near perfect bottom end. Even the rod bearings looked near new. The heads had no cracks so I cleaned all the parts and dropped off the heads and cylinders at my buddy's shop, Sportcar Service, here in Colorado Springs. The plan is for fresh exhaust valves and a valve job as well as honing of the cylinders. I also placed an order for the gasket kit, water pump, t-stat, fuel line kit, motor mounts and a few other odds and ends needed to get the motor freshened up.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

While I'm waiting on parts and machine work, I'm digging into the Bus to see what needs to be done. It doesn't happen often, but this Westy surpassed my expectations. It appears to very complete and optioned. I began where the previous owner left off and removed the interior for some rust repair.

I don't recall ever seeing one of these single middle seats:

It came with AC, which was a bit of a challenge to remove:

This adorable ice tray!

One of these things. Any ideas?:

Once most of the panels were removed, I stashed the mess in my little trailer until it's time to be re-installed.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

So with a non-running Bus that has no interior and needs rust repair, I did the next sensible thing and found a set of 16's on Craigslist:

These are going to machinist buddy to open up the centers to fit the Vanagon hub.

I'm still formulating a plan for the rust repairs but I'll be tackling that as I put the motor together.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[DanHoug]

i've got one of those middle seats with the locking compartment in grey. very cool option.

aaaand... anyone that has both VWs and a BMW motorcycle AND a built in parts washer in their workbench is going to be juuuust fine with this project!

-dan
(81 R100RT, complete with dual CHT, turn&bank, working airspeed gauges and of course an aircraft compass)

[novws]

Cool project! Looking forward to following your progress.
_________________
88 Vanagon tintop Subaru ej25
82 BMW 323i
02 Subaru WRX Wagon

[Mellow Yellow 74]

[Bulli Klinik]

[Bulli Klinik]

[Bulli Klinik]

And thanks to all for your interest! I enjoy watching projects unfold on the forum and I hope I can do my part to add some content.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

After speaking with my machinist buddy, I've decided that I don't want to use the 16's. By the time they are centered on his mill, the centers are cut, the lug holes milled out, spacers, studs, etc... I don't think that it's going to worth it to me. I'm still debating what direction to go. I've even considered keeping the 14's. Though I want some big tires on it, I'm on the fence considering I'm only going to be running a 1.9. I understand that BFG doesn't make an All-Terrain in 14 anymore. Does anyone have any feedback on the Maxxis Bighorn in 14 or a similar off-road tire? I may delay my big wheel/tire dreams until I go up in horsepower in the future.

If anyone is in the market for some nice, steel wheels, let me know.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

My first order from GoWesty arrived:

Still waiting on the machine work, but I imagine it will be done by the end of the week. Looking forward to getting the motor back together.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I also came up with a plan of attack for the rust repairs on the long side. The rust seems isolated to the seam and I was surprised to find that lower portion of the rocker was in pretty good shape. What I plan on doing is carefully removing the rocker and repairing the rusty upper section. Once the rocker is out, I can repair the lower flange of the upper panel and metal finish that portion due to the lower rocker being removed.

If I were to replace this with a modified Klokkerholm panel as I've done in the past, I couldn't reach up to planish the welds of the upper panel as the panel is one piece up to the lower swage/belt-line. There is nothing wrong with using the K-holm panel and putting the weld in the swage, but good luck doing any finish work once the panel is welded in. On a side note, the K-holm panels seem to be somewhere between 20-22 gauge. A little on the light side.

Here is K-holm panel modified to work properly. The forward section which covers the B-pillar is removed and capped. A flange is added to the inside in order for it to attach to the floor:

Once it's in, it's in and you can't access the welds without very, very long arms.

This Van was VERY rusty and needed the whole panel and more. It's currently back on the road with a SVX and a very happy owner.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

With a plan formulated, I got started cutting out the rust. The inner panel support was drilled out as well as the lower portion of the rocker. The rest was trimmed out with a cut-off wheel.

Happy to find both the B and C pillar in good condition.

Fat Albert doesn't like his beauty sleep disturbed.

_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bulli Klinik]

I generally like to strip paint with chemical stripper. Unfortunately mine has been sitting on the shelf a bit too long and wasn't as aggressive as usual. I'll deal with it once the welding is done.

I sheared a piece to tack in and did just that.

I like to planish as I go along to keep things straight.

That's it for now. Next step is to fully weld, planish then brake the flange line.
_________________
I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[raoul mitgong]

Odd but the BFG KO2 has a smaller 16" (27" OD) option than available in the 15" (27.6" OD).

-d
_________________
84 Westy with a 2.1 (Groover)
86 Tintop Syncro (Crow)
86 Tintop Syncro to Westy project (Tom Servo)
91 Westy (Only the top 12 inches of this van (a burn victim))

[DanHoug]

Gasgacinch on the counter.......

-dan

[Bulli Klinik]