Chassis Rebuild

[Clatter]

OK,

Putting together a big/long build thread here of a "quickie re-do"..

Many here get a "new" bus, and want to take it camping right away..!
Lots of times it's 'lipstick on a pig' - pretty, but needs real love.
Other times, it's a 'survivor' or a battered field/barn find..

Either way, the running gear of any bus should be job #1.
You can't be going camping if you don't have brakes, steering, etc.


My good friend Damon here provided us a perfect example of what this takes.
He has three kids and an ex-wife to pay,
So we have to do this on the cheap.
He's a house painter, and showed up driving a Subaru??
We did a motor for his bus a few years ago, and he was driving it daily..
So what happened?
He says a CV was making noise...

Follow along, as we check out "A CV is making noise"...

May 19, 2018..
Bus on-site, up on stands, wheels off, and disassembly beginning..

Sure enough, an initial check reveals a sloppy swing lever and some wasted balljoints.
Try and smile, Damon! you're having fun!!

What's this? OG rear torsion bar bushings from 1978 are wasted?

Who woulda thunk it??

Stay tuned for more,
Or,
Better yet,
Click to the next thread...
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Bus Motor Build

What’s That Noise?!?

[Clatter]

So,
We left off with our rear suspension coming apart..

You lever the spring plate off of the lower stop,
But,
Before you take the spring plate off,
Check it with your Sears cheapie protractor/level dealiebobber.
Need to make sure this thing goes back on correctly after we clean it up and stab new bushings..
If what spline it goes on gets messed up,
We could be hosed.

Also like to take a reference pic or two,
And scribe a line where it sits..

Be careful levering the spring plate off of that up-travel stop,
it can bite!
We'll show a couple of tools you might use to put this back on, when the time comes;
Plus, it will get a click or two of lift,
As the ass-end of this thing was sagging.


Rear shock was siezed into the (aftermarket) rear sway bar mount..

Easy enough to dispatch with a press.
Don't want to mangle things with a hammer if we can avoid it..

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Bus Motor Build

What’s That Noise?!?

[Clatter]

Here's another one of those crappy things an old bus just loves to do to waste your time,
And make life annoying...

The rear brake adjusters seizing!

Who knows how bad this bus was stopping, with no rear brakes??

Instead of the brakes getting adjusted, the rear holes get mangled instead.

Spinning these off using a big pry-driver was downright difficult, even here on the bench.

Even with the center piece out, the star adjuster thing was still stuck tight in place.
Taking a long M8 bolt, threading it in until it bottoms,
Then turning it HARD down thru the adjuster forces it out.
(If that makes any sense..)

Clean up the area in the old blasting cabinet.

And lay a bloob of weld around the outside.
This will be hard/tough, so the hole doesn't get mangled again,
Plus,
Makes it the right size/shape for the rubber plug again.

It got ground down (mostly) smooth again, with a pointed stone in a die-grinder and Dremel,
But i forgot ta take a picture o' that..
We'll get that next time we're out there...
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Bus Motor Build

What’s That Noise?!?

[Clatter]

OK, we're up to May 28th now..

Parts are scattered all over the lawn,
And the Gas Bucket is coming out..

Egad, a lot of work..!

The only 'new'-er part, the German master cylinder, still looks good!
Looks like the brake booster is a good part as well!

YAY! We get to leave something well enough alone!

This here can be a PITA, getting the upper trailing arm off.
First, put a jack under the ball-joint, and slip the up-travel stop out..

Then, you can hammer the arms off from behind, one at a time.

Pressing the rusted-on adjusters from the upper ball-joints is hairy.
They go BANG! when they break free all at once!

There was also an old abandoned A/C system involved.
It was useless and added weight, while taking up space,
So it had to go.
Damon was LOVING getting the old coils out from under there.
(Sorry didn't get a pic).
The hoses all by themselves kept me busy for a while no doubt.

That led to removing the layers of old PO front carpet, pad and mats.
in their sizeable wisdom, the PO decided to use a bunch of sheet-metal screws to hold the carpet in..

So there you go,
A couple of big days' work, by a couple of reasonably capable guys,
And what do you have??
More room for the dog to nap...

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Bus Motor Build

What’s That Noise?!?

[Clatter]

Calipers need to come apart (obviously).

Once getting them apart, looks like Girling rebuild kits are NLA..
Another call to the community to see if anyone has any ideas where to get a kit for these..
ac.net and Bus Depot both say NLA.. The letters we all hate to hear..

These calipers are in good shape otherwise.
No stuck parts, no stripped bleeders, shims not missing, etc..
Shame...


Go! Damon, Go!!!

Bus recently got front rotors, so they had plenty of meat left.
Our hero Jim at Napa Carr Parts here in Santa Cruz dialed us right in.

He also popped out the old ball-joints, for when our new ones come in.
Made sure to mark them, so we know which side they are supposed to be pushed into later.

They got what little paint they still had cleaned off when cleaning grime,
So we decided to paint or powder,
So that meant masking for blast.

Also got some other stuff masked off for blast.
The seal surfaces get wire-wheeled first, to get the crud,
Then polished with 400-600-800-grit paper,
Whichever it takes to get them shiny and perfect,
Then duct-taped off, so blasting doesn't hurt the shine.

Drums were a little older..
Max size:

Measured:

On the money:

Mint!:

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Bus Motor Build

What’s That Noise?!?

[Clatter]

More A/C system removal efforts...

I had a day off of work, and gave it a big one up under there!
Dirty work, and welding/grinding sparks everywhere upside-down..!
Where is that damn Damon anyways!?!?!


First off, making up some plugs for the big holes they drilled for refrigerant lines:

Clean up the area for weld:

Zap Zap:

The A/C people used sheet-metal screws to hang everything.
Look how clean this bus is up underneath!
Any little sheet-metal screws make holes, which can give water a chance to creep in,
and start rust.
(capillary action is NOT our friend here).
Also note how a PO used sheet-metal screws to hold down the carpet.
Here we are, now is the time.
If not now, when???

Up under rear fender:

The very top one here was scary.
The gas tank is right behind there!
I -almost- just left it..

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Bus Motor Build

What’s That Noise?!?

[Clatter]

This was early Saturday June 2nd, at like 6AM.
I was all stoked from the Bug-O the previous weekend.
Take inspiration when it comes!


Part of trying to save money is re-using OG German parts (if still good).

Mark drill starter divot with punch.

Grease drill bit so chips don't get inside.

Grease tap so chips don't get inside.

Install Zerk.

Carefully remove retaining ring, clean and save.

Toss old boot.

Clean up boot side of joint.

Pump grease in as goddamn motherfucking hard as you can, while wiggling joint to get it thru.

Pack more grease in the boot side.

Install new boot using cleaned old ring.

All six done.

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Bus Motor Build

What’s That Noise?!?

[Clatter]

I found some good CV joints in my stash..
Damon's were wasted!
Never saw a set like that in all of my years' junk-dogging..
Will try and remember to get a pic.

Almost done cleaning..

Almost done cleaning..

Almost done cleaning...
Smile! You're on the Internet shirtless at 55! LOL!

It's OK.. Next time help more and I won't do this!

All of the cleaned parts are loaded up and dropped off at the blaster's.
They promised it all on Friday.

Parts keep coming in,
This is what, our 5th order of parts now??

Got some gloss-black DuPont/Axalta proper paint for stuff that won't go to powder.
Things like the beam, tie rods, rear trailing arms;
All of those things have plastic or rubber parts that will melt in a powder-coat oven.

I know some of you (Damon included), will say it's over-kill to be painting all of this stuff like that.
It will be a couple hundred for paint and powder no doubt.
But look at this pic right here:

Those shiny spots are bare metal.
It will need something.
Rattle can sucks. i don't care what kind you use.
Might as well just pee on those parts as put anything on from a spray can.
Poor-15 is vandalism. it looks worse than rubberized undercoating or spit, IMHO.
Plus, it's goopy and thick and goes on with a brush FFS.
Must... not.. Rant...
Anyways,
We will use real car paint over stuff we cleaned in gas and carb cleaner as well as possible.
Unless it gets blasted and powder-coated.. Or blasted an dpainted..


I don't do no half-ass work.
Go somewhere else if you want to use rattle can.

Plus,
Now's the time.
If not now, then never!
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Bus Motor Build

What’s That Noise?!?

[Clatter]

Yesterday, June 6, I had me a day off..

Since the Girling rebuild kits have gone the way of the dodo,
I remembered this old beam I had from a bus I cut up a couple of years ago;
It has a set of ATE calipers on it, thankfully.

Here it sits under the lilac bush, rusting to a solid block..

It took most of a day to impact-hammer that sucker apart.
Since it was sunk in the muck, and too heavy for me to extract alone without getting a hyena..
I rassled it up under that bush.

After a dirty day of cussing and skinned knuckles, i got a set of trailing arms, spindles, some rotors, a brake booster and master,
and maybe a beam, but.. who cares, i guess..

Unfortunately,
Some dumbass rednecks were into those calipers already.
They over-tightened the bleeder screws, so they broke off,
Plus,
They lost the shim set, too..

So,
Not really sure these ATEs are worthy cores or not...

We'll see if some extraction magic can be worked on the bleeders,
And maybe get some of those cool shim sets that one guy makes..?


So there you have it.

There's always something to come along and stop the show.


We are going to be clear under the whole car,
And,
Between the two of us,
It'll be a few more than fifteen days, methinks..


Link


WELL THIS LIFE IS ONE BIG AUTOMOBILE
FIFTEEN DAYS UNDER THE HOOD
SOMETIMES IT’S HARD TO BELIEVE IT’S REAL
FIFTEEN DAYS UNDER THE HOOD
WELL I’M WAY DOWN HERE WITH MY FEET IN THE AIR
I GOT GREASE AND OIL ALL IN MY HAIR
IT’S GETTING SO BAD, I’M STARTING TO SWEAR
FIFTEEN DAYS UNDER THE HOOD
WELL I’M AWFUL HUNGRY I WISH I HAD SOME BEANS
FIFTEEN DAYS UNDER THE HOOD
I SPENT ALL BUT A DOLLAR ON VALVOLINE
FIFTEEN DAYS UNDER THE HOOD
I’M LUCKY I SAVED A BUCK TO GET SOMETHING TO EAT
TOO BAD I’LL SPEND IT LATER
ON WHEEL BEARING GREASE
A COP JUST TOLD ME TO GET MY CAR
OFF THE STREET, FIFTEEN DAYS UNDER THE HOOD
WELL I WENT DOWNSTAIRS I PUT ON MY GOOD PANTS
TO GO TO THE JUNKYARD FOR A VACUUM ADVANCE
I WAS JUST CLIMBIN’ INTO THIS SHIRT
WHEN I REMEMBERED I COULDN’T GO
BECAUSE MY CAR DON’T WORK
LET ME TELL YOU FRIENDS WHAT’S WRONG WITH ME
FIFTEEN DAYS UNDER THE HOOD
I JUST DROPPED THE CRANK SHAFT ON MY KNEE
FIFTEEN DAYS UNDER THE HOOD
I GOT WATER IN MY OIL AND THE LONDON FLU
BURNT VALVES, VAPOR LOCK, WORN BRAKE SHOES
I GOT THOSE DEAD-BATTERY-BROKEN-FAN-BELT BLUES
FIFTEEN DAYS UNDER THE HOOD
WELL I’M TRYING TO GET THIS ACCELERATOR CABLE FREE
FIFTEEN DAYS UNDER THE HOOD
ANDY GRANATELLI’S ON THE RADIO FOR S.T.P.
FIFTEEN DAYS UNDER THE HOOD
I’M LOOKING FOR THE FLASHLIGHT FOR THE TIMING CHAIN
I JUST SKINNED MY KNUCKLES AND I’M IN GREAT PAIN
IT’S AWFUL COLD AND IT’S STARTING TO RAIN
FIFTEEN DAYS UNDER THE HOOD
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Bus Motor Build

What’s That Noise?!?

[WildIdea]

Excellent information. Thanks for posting.

[twinfin]

Steve! Your an Animal!! and good friend too. Many thanks to you for motivating me to keep The Blue Sub and hold my hand through this Chassis Rebuild endeavor. Many a Surf Mission still await the Sub. Also much thanks to your wife for allowing this to happen in your yard next to your Fastback build!
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________________________________
"It's knowledge to learn from your mistakes. But it's wisdom to learn from others!"
------------------------------------------
“He that goeth to bedde wyth Dogges, aryseth with fleas.”

"The Blue Submarine"
1977 Campmobile, Type 4 2.0 liter Federal, Non-Catalyst, Fuel Injected with Valvetrain from the type4store, 411 Heat Exchanger Preheaters, S&S Header, Supertrapp Silencer. ...and a lot of help from Clatter and TCash and friends!

[cmonSTART]

This is a great post to illustrate to a new owner the minimum of work that's needed to put one of these on the road safely. It's great that you're documenting it here!
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'78 Bus 2.0FI
de K1IGS

[SGKent]

good work and attention to detail.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Clatter]

Little bit of back-story..

Gads, this was over four years ago!

Damon's motor was done to the short block, with barrels and heads;
The lower end was left alone, as the end-play was good.
Check out the vintage big-bore S&S header.. He runs a Supertrapp on it.

He went the distance with cleaning the injectors, sorting the FI wiring harness, etc.
The thing ran great for four years of daily driving and work-truck use.
Still has plenty left, no doubt..

Here's where my rant comes in (Imagine! ME ranting..! )

So many times, there's this new user showing up.
ESPECIALLY on the Bay Bus Forum..
They just got themselves a lipstick pig, or a bus from a field.
They might have gotten the motor running,
Or bought it running,
But underneath, it's just like Damon's bus here.

It's always TOO funny to see these people.
(Not just millennials, either, there's plenty of midlife-crisis types, too),
"We just got our new bus home, and started right in restoring it!"
"It got all of the rat-poop cleaned out, we made some really nice curtains to match our new upholstery fabric".
"Once we get our solar panels dialed in, we'll be ready for endless vanlife camping adventures".
"After our USB phone charger and LED lights are finished, we'll have it 100% restored and ready!"


ANyways... Enough bagging on the plastic-bumper citizenry..


We will be working on the bus this Saturday.
The legendary TCash has promised to make an appearance ( )
And I'm currently hassling Chris "old DKP Driver" to make it.
If anyone in the San Francisco bay area wants to volunteer to learn a thing or two,
We will have BBQ and free beer this weekend.
Swing lever rebuild, and steering box adjustments are advanced busological skills to be put on display.

So,
If you want a free place to camp in Santa Cruz, or just stop by,
We'll be there.
PM me for details if you're interested..
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Bus Motor Build

What’s That Noise?!?

[raygreenwood]

I have had the same rant!

I see people all the time...whether bus, bug or whatever type of ACVW.....and they buy a car that may be complete....but has not run in eons.

The first thing they do is fill it with gas (without checking the fuel lines, tank, carbs etc).....and spend all day cranking on it trying to get it start. And it may start.

Now .....what may have been an OG engine or a well built aftermarket/OEM combo with low to moderate miles....super parts etc......is now requiring a complete bare minimum top end rebuild.....to replace the rings that were ground up on the rusty cylinder walls.....and the rusty cylinder walls that may have only needed a nare minimum rehone to clean up the surface...and are now scored and need to be replaced.....and or the valves that stick in the guides due to varnish....and the resulting bent pushrods.....and pumping whatever oil/water/rust....slush that was in the crankcase....through the cooler and bearings.

They get in a hurry. Instead of towing it home....spending 4 hours and draing, pulling the engine and popping off the heads to inspect.....they make junk of what could have been simply a re-ring, new gaskets and lap the valves. Ray

[SGKent]

yes - agree. Colin and I were replacing his clutch and pilot bearing last night on his late Westphalia. It started failing about Tracy on his way north. The sound he was getting we both thought was the pilot bearing - it was. It only chattered for a second with a few small-hammer-on-a bell-like-rings right as the clutch engaged under load. Fortunately he is audio conscious like many of us, and he caught it before it damaged the input shaft. The needles were starting to come out. He showed up about 5:30, had pizza, and we were done with him back on the road about 11:30. New clutch disc, TO, seal and pilot bearing - all parts cleaned, and glass beaded or cross-hatched where applicable. Good for another 80,000 miles.

We discussed how so many folks buy these buses with no idea how they will be able to fix them properly or get them fixed on a trip if something fails. Sometimes just finding the parts can be a challenge. It is nice to see folks learning how to maintain their buses, mostly from necessity, but that cartoon "thinking of buying a VW van, no bus" with the bears should be mandatory when someone joins TheSamba.

Glad to see the bus in this thread getting the "chassis and other" go thru to deal with those things that need to be done. It will help minimize future disruptions to travel.
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[twinfin]

I do not want any "Millennial's" touching my BUS!!!! Everything they touch turns to Crap!! I ought to know, i have one and he isn't done yet.
_________________
________________________________
"It's knowledge to learn from your mistakes. But it's wisdom to learn from others!"
------------------------------------------
“He that goeth to bedde wyth Dogges, aryseth with fleas.”

"The Blue Submarine"
1977 Campmobile, Type 4 2.0 liter Federal, Non-Catalyst, Fuel Injected with Valvetrain from the type4store, 411 Heat Exchanger Preheaters, S&S Header, Supertrapp Silencer. ...and a lot of help from Clatter and TCash and friends!

[Clatter]

Had to run by the house at lunch today..

Dropped off a big box of freshly-blasted parts.
All of this to get painted,
But a few things, like front trailing arms, sway bars, etc. are left at the powder coater's.

Made up a harness out of a trailer wiring kit and some split loom last night;
to install gauges.

Stopped by the house to drop off blasted parts,
And look what's going on..
Pressure-washing fun!!

Whee!!

Damon and I both went and bought a box of Scotch-Brite and some cans of rubberized undercoating..
More big fun to come!
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Bus Motor Build

What’s That Noise?!?

[Clatter]

Damon was gone by the time I got back from work.

Five hours later.. I got some paint down. June 8, 2018.

The undercoating applied by the PO got stripped off in a lot of places by the pressure washer.
Obviously, they didn't put as much effort into prep as they coulda.

First, the freshly-blasted pieces need a good hosing-down with some compressed air; to remove the grit and dust from cracks/crevices.
I followed that with some phosphoric acid,
Then a fresh-water rinse, and some more compressed air,
plus some good California Friday afternoon sunshine (and a masking session)..

FatDog is one word, not two, BTW..

One annoyance was a not-diluted-enough phosphate wash.
I unfortunately didn't add as much water as I shoulda;
because it left a chalky residue.
It was a PITA to chase it with a Scotch-Brite and compressed air,
Mostly because I shouldn't a had to do that..

Got out all of the paint stuff, and set up the painting station:

In the end,
It came out quite pretty.

On those rotors, i tried to stay away from the pad contact area,
And wiped it down with a solvent-soaked rag where the pads might touch.
Those brake pads will handle the rest well methinks..

This is just single-stage gloss black DuPont car paint.
No epoxy primer, no clear coat.
If i didn't have a half-gallon of it sitting around, it mighta gotten semi-gloss?
Hopefully, it will protect these parts for a long time to come.


Will get up early tomorrow, flip the parts over and paint the 2nd side of 'm.
The beam, tie rods, drag link, splash pan, booster, etc. will also hopefully get shot tomorrow as well.
But,
Only after the legendary Tim Cash shows this humble apprentice how to do a swing-lever bushing replacement,
And a proper steering box adjustment..

So stay tuned,
The professor is about to hold class...
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Bus Motor Build

What’s That Noise?!?

[Joey]

Wow, great work!

I wouldn't apply rubberized undercoating. Over time it can crack and trap moisture.
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Joey

‘60 Kombi - '74 Bus - '79 Panel - '65 Beetle