Bostig Conversions - Post modifications here

[JudoJeff]

Post any modifications you've done to your Bostig conversion here.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Modify the air box to reduce noise.

Simply put, you install sound deadening inside the air box and modify the air intake. All can be reversed if you hate it.

Supplies:
FatMat or equivalent
2.5"to 2" rubber plumbing reducer
RTV
Clamp
nylon ties

Cut the reducer down.

Insert into the air box:

How it'll look

Stick sound deadening into box, top and bottom, don't block the filter.

You can put RTV around adapter, then lightly clamp hose to it:

The hose goes up and under the driver's side, tie it down with the nylon zip ties. You can point the opening towards the front or the rear, you pick.

It's very subjective, but I find this much quieter. Note that I also covered the outside of the resonator with FatMat, and painted it black. (no photos)

Edit May 28: so, pointing the air input hose towards the tire was one of my dumber ideas, NFG. Got into a torrential rain storm and Zetec started to skip. Laid in the mud and yanked off the hose! Install the air hose end someplace where this won’t happen. I’m looking for another air box to try a more snorkel approach.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Dan Gravelle came up with this and I like it.

Parts:
new muffler hangers:

Here are the parts:

Summit Racing:
   WLK-17904 , muffler
   2-WLK-36273, clamps
Amazon:
https://www.amazon.com/gp/product/B000CQDL94/ref=od_aui_detailpages00?
FLAPS:
   2-3/16x2" bolts with fiber lock nuts
   2" muffler clamp (never liked the one that came with the kit, this one is solid)

The pictures show what Dan did, no explanations necessary. The Bostig recommended muffler clamp is $18 at FLAPs, so not buying that will help cover these costs.

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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

The vacuum inlet saves you lots of trouble with the Ford OEM "Chinese-finger puzzle" vacuum fitting. This is a modification you should do during engine prep, not once you've installed it. This takes all of five minutes.

Drill with 1/2" bit
Pic or small screwdriver
RTV
Vacuum inlet

Here's the inlet:

Ford's troublesome hose connect on intake manifold:

So during engine prep, drill straight in with a 1/2 inch drill bit, go slow, and you'll know when the fitting is off:

Pick out the rest of the plastic and the metal washer thing:

A little RTV on it, and tap into place, then heat up a nail and melt the edges around it.

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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[Bassyaks]

I threw the stock hanger system out after the first ride, too much vibration , I went with a regular hanger at the inlet and a hanger from the tailpipe to body using rubber donuts. Also added this cold air intake, it felt like it made more power.

[jimf909]

Great thread! I like the air box mod as it seems like a source of noise under some conditions.

Muffler heat shield I made in an attempt to reduce temp of the a/c compressor. I haven’t measured temps but it seems like it would be helpful. (I’m intrigued by the Catifold or Manicat that I’ve seen in the fb page and will be interested to see an install.)

Aluminum sheet cut and bent to wrap around the muffler and hopefully deflect heat away from the a/c compressor. There’s still a bunch of heat coming off the cat and I don’t know how the air flows in the engine compartment.

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- Jim

[JudoJeff]

The power steering reservoir moved inside the area where the air box used to be, gives you a better angle on the AGFA hose. Much easier installation of the power steering pump, and all but disappears .

I did this with the taillight off. Two pieces of scrap aluminum, screwed into the opening, and the reservoir bracket then attached. Sorry the photos aren't very good, but you can finagle your own setup.

The white hose is the BlazeCut system, I've already burned down one unit, so I'm a bit paranoid.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Trim Firewall for better access before doing the install. I cut up and across to make a bigger opening on the passenger side. The photo is poor, but you can extrapolate where to cut it. Use a file to dull the edges afterwards, and protect your hands. Now you can remove/install the starter without going under the van.

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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[JudoJeff]

Similar to Jimf909's very elegant heat shield, but more Mickey Mouse.

I took L brackets, maybe 3" on a side, and bent them into a U shape, with one side lower. Drilled a hole and attached them to the compressor, using the compressor's mounting bolts. Then bent an old cooking sheet into an L, and attached it. You could also use an old license plate.

Note this is an offset muffler, not the standard Bostig recommended one. Cost about $20

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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[MsTaboo]

A couple mods that I posted in the Bostig tips & tricks section awhile ago.

The p/s reservoir move. Simply add a spacer to the stock Bostig holder.

Airbox mod.

Overflow bottle. Gives more room around the air box.

For Syncros, makes for more room around the coolant pipes.

Also for Syncros, sealing the bell housing for water crossings.

And the new bell housing vent location.

And the a/c hose routing around the rear of the engine.

I also moved the muffler over like others have and used the smaller one found by Lemoncove (I think )

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Currently:
'90 Syncro Westy 3 knob w/Zetec

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[jimf909]

Has anyone installed an alloy(?) valve cover? I’ve needed to replace my valve cover gasket about once a year. I’ve heard the alloy cover helps but I’m also open to other ideas.

Thanks.
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- Jim

[JudoJeff]

Mstaboo, very nice and excellent photos!

Jimf909, what happens to the cam cover gasket that it fails? These are pretty solid. I use a dab of RTV on each corner when re-installing the cover, and torque it down carefully.
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________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[detoxed]

MsTaboo, Thanks for the clear concise pictures. Very helpful!

[jwallis]

[MsTaboo]

[MsTaboo]

[JudoJeff]

MsTaboo,

I noticed you're not using a fill tower, tell me more about your arrangement. How do you fill the system, via the radiator vent? I have an old style fill tower and bracket if you want it. (cheap)

P.S. engine bay much too clean!
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[MsTaboo]

My engine bay is a combination of Bostig kits. I have upgraded various parts of the system over the years. My original system was a Group 6 with the tubular engine cradle, first low profile oil pan, ECU within the engine bay, etc.

The coolant fill is from the 2010 kit and is integral to the thermostat housing at front of engine. (you can see it in front of the oil cap) That was an upgrade from the earlier setup!
Someday I'll probably buy the latest fill/tank combo, but that means also buying the aluminum thermostat housing ($$) as I don't want to go backwards to the stock plastic Focus housing.
I haven't change it out yet because it works fine. Thanks for the offer!

Original '09 install

First upgrade

Latest

One of the mods I would really like to see would be a new downward projecting exhaust header to help get heat away from the engine lid.
I've been contemplating going to an exhaust shop and having them fab something together- none of the aftermarket Focus/Zetec headers will work.
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
Help the fight against Truth Decay.
Defend democracy, support Ukraine.

[buildyourown]

[kourt]

Are you all aware of the new Bostig header/cat combination, using a 2002-2007 non-turbo Mitsubishi lancer manifold?

https://bostig.zendesk.com/hc/en-us/articles/360000349766-RG9-SK-E-and-rockauto-order-list

(you'll need to set up Bostig Zendesk credentials to view this article, but it's worth it)

Not totally ready for market, but this is where things are going with the header/cat system.

kourt