My Aircooled Vanagon: Hated by All, Loved by Buggeee

[Buggeee]

Now, you all know the saying right?

By the time I am done, I will be ready to begin.

So the FIRST time I painted the face I was, well, less than patient.

I decided to throw out all the advice about painstaking preparation and multi-stage paint process that my cousin the retired career body man had been feeding me and said to myself - "Self, this is just a practice van."

I got a single stage enamel, I quickly sandblasted all surfaces lightly to "roughen them up" (OMG Whaaaat?). A little bondo there, a little epoxy primer here...

And then, that same evening, feeling real good but running out of sunlight, I figured it was time to immediately hit it with three heavy coats of enamel.

Looking good right?

That's because you are standing thirty-five feet away. LOL.

Lets walk up and admire the work...

Ohhhhh Nooooo. It's Shiitake Mushrooms. LMAO I suck!!!! I can't even show this thing in public at a campground.

Plus, now all the evening bugs are sticking to the front end like flypaper!!!

What to do, what to do... I've Got It! The paint gun is right here.

I will further bury this in a few more coats of epoxy primer and that should fill in the low spots right?

Hello?

Rough crowd.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[dobryan]

Man you sure like making more work for yourself.
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[danfromsyr]

soo how many times you hit that towball sticking out with your shin.
_________________

[Buggeee]

Well of course a few more heavy coats of epoxy primer over a few hastily applied heavy coats of enamel over a couple of coats of epoxy primer was not a recipe for success.

Six days later the nose of my van was still accepting my fingerprint as proper identification. Just press right here. Or here. Or anywhere. Its all thick playdough, and its all over the face of my van.

...so I hung my head, and I cried, and I hung up my paint gun and put the mess up on Craigslist and apologized to my wife and couldn't look my son in the face and...

Screw that!!!! I walked into my Garage and grabbed a gallon and a half of chemical paint stripper and went to work. For good measure I also bare metaled the hood of my bug - parked nose out in the apron of my driveway just to see the curtains pull back from the living room across the street (Tee Heee Heee). "Waz he up to now?"

I'll tell you what he's up to. He's going all in. He's in full COMMIT mode. He's bare-metalling the front of that mess of a camper AS WELL AS the bug in the driveway. That's what he's doing it. And he's doing it with good cheer. and he's doing it before sundown after work. So get in or get out of the way Peeps.

I decided this time around to take the time to do it right. Many steps, over many days, with different grits of paper and what not. Here's a shot of the sandable build primer as a post card from the experience.

And this time around its base coat / clear coat. Color on. Sand down the (minor) orange peel as needed between coats. Clear on.

Looking better right?

NO! Weren't you listening?

I'm talking full COMMIT here. Lets sand that clear a bit with million grit paper and go deeper in the mirror with more coats.

Oh yes. Here it is.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

[Buggeee]

Having found the wonder that is clearcoat, I blasted and painted the underside of the front bumper and then polished the outside as best I could with aluminum foil (the chrome is mostly wore off) and cleared that thing, along with clearing the headlight rings that had been sprayed with rattle can.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

Some parts have arrived.

But before assembly of the nose, there is an eviction to be served.

I'll rest my fingers a spell and quote myself from another thread:

[Buggeee]

Alrighty then, lets build this face:

Oh wait!

Hold on, I almost forgot. Yes, here it is. Forgot this but I'm really pleased with the idea. In addition to the outside seams, I sealed the backside of those fenders again

Before seam sealing I hit all the seams with internal frame coating. I also drilled two holes on the left as necessary and internally frame coated the bottom side of the windshield corners and the inside of the nose. The right side had access through the wiring grommets. I am sure my wiring is all jet black now but the sheet metal is sealed up. Then I plugged the holes with rubber plugs.

Ok, now lets build this front end!

If you look closely you will see that the right fender seam I welded in completely because the prior repair panel replacement was not sitting exactly square to the front hood and needed some metal work to get it straight, according to COMMIT. I did not care to try to create a fake seam there so that is my signature on the project now.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

Good Eye

Good Eye

Yes, that is a fresh looking luggage rack in that last picture.

In the meantime, over a many week period, I had been working on the top down in the back yard.

Again, I quote myself:

[Buggeee]

Here is some paint porn to illustrate the signature lack of driver's seam. Deal with it.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Vanagon Nut]

really enjoying this thread. Subscribed. People don't always show their mistakes. I think its really useful to see what can go wrong and why it did.

As an old boss once told me, paraphrased poorly:

'if you never make a mistake, you won't learn how to fix the mistake thus you won't truly learn the process'

A portable sand blaster sure sounds like a great investment.

Keep us posted.

Neil.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

[Buggeee]

Of course, it needed canvas.

There are lots of threads on installing canvas. So, I won't test your patience any more than I have already with the ins and outs of it.

However, here's a bit I found useful and hadn't seen before. I suppose its out there already but I felt really good when the light-bulb went off and I figured this out.

I had stapled mine on the ground, right side in (whew, dodged that bullet!) and then had a few neighbors help me load the top onto the van.

I was having a hard time with the spring loaded support bar as it's sooo long and was really concerned about scratching the paint, until this happened:

Yes. I had a cup of coffee.

Huh? Oh the other thing. I folded over the support with one hand and threw some zip ties on it with the other hand (thereby proving that I have an opposable thumb, and know how to use it!)

Then I sat the roof on a clean bucket and set the support in place for installation. No muss. No fuss.

As for those stupid little round retaining clips on the pin at the bottom of the support rod, here's what I did (again, probably out there already). I used the right size socket to fit the outer lip of the clip, and then just squeezed it on with some channel locks. No muss. No fuss. (The first time I did this I was hammering it with a hammer like a dufuss. I liked the other support rod I had better so I got to do it again.)

Screwing down the bottom of the skirt is a PITA no matter what. Here's my take on it, said before.

[Buggeee]

Details, details.

I had to replace the washer pump. Before I could replace the washer pump, I had to make up a bracket from some gas tank strap because the tabs had long ago cracked on the bottle. So...

The first time through I could not figure out why I was not getting water from the nozzles. I started to de-bug the wiring and was about to get into the wiper switch on the column when.... I discovered wiper fluid all over the lower front of my van pouring out of the grill. Huh?

Here is what I found:

PO PO PO WTF????

Up to NAPA for some hose.

Also, as a bit of background, I had stumbled on the following link at some point:

https://www.transportermagazine.com/2017/01/10/upgrading-vanagon-windshield-squirters/

In which a Vanagon hack is laid out using windshield nozzles from a Suzuki Sx4, part number 38480-56K00. Each nozzle has three nozzles! I got some.

Check this out:

Cool right? I know. It's Bitchin.

You know how many pictures I took trying to capture that? A lot!!! Its ok though I get a discount on film and developing at Walgreens. (If you even cracked a smile at that you are ancient my friend).

You know how long it took me to adjust all those nozzles? An hour!!! You know how much wiper fluid I went through before I went to wasting plain water? Three gallons. Then I had to do it again because water sprays differently than wiper fluid. Take my word for it, or do it again. Those are your choices.

It was worth it. I used this, which was left over from my top install:

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

I am catching up in time so this next part is still a little fresh to talk about really but the fuel system had arrived while I was making it water tight and with a pretty face.

While I had the tank out, I decided to freshen up and protect, to some degree, the underbelly of this ancient but mostly dry camper.

So I soaked the whole undercarriage in phosphoric acid and then power washed it

A couple weeks later I sprayed everything I could get to internally with two foot long tubes spraying Eastwood internal frame coating and externally with Eastwood Chassis Black.

Some people like to lay on their back and look at stars. However, I also like to lay on my back and look at this ("Be right there in a minute Honey!")

That picture also serves as proof that I replaced the shifter bushings while I had access with the tank out. Look closely right in the center, the only colorful object. Thank you very much. I think so too.

Also taking pictures of stuff coming apart is a really good thing to do. It had been months since I dropped that tank some of the details had gotten fuzzy on me.

Here I am trying to figure it out with the Bentley, not having much luck.

And here I am trying to figure it out with a picture I took at the time, now printed out in black and white as my own supplemental insert to the green book, BINGO

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

As an aside, it was cold out one night and I broke the top off one of the float valves on the passenger expansion tank trying to get it installed.

Shiitake.

Bet its NLA. I buried it in two part 2,000 lb strength epoxy, covered it in Gorilla Tape and submitted to being some other owner's prior owner, if you know what I mean. Forgive me, I was tired.

When I woke up I did the research, ordered a new float valve, and made it right.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

All new injectors going in!!! (the old will be sent out for rehab and kept as replacements)

Of course, seals too. All new rubber fuel hose, plastic fuel hose, fuel pump, filter, all vapor hoses, intake boot, throttle body seal. EVERYTHING.

Here's pics of my twisted mistake in assuming I was replacing all the lines with the rubber hose kit, cutting out the plastic tubing as well. OH MY. I was a few inches short on the last run. lol.

What? Are you kidding me? But I just said I did it

Fine. I'll go push the freakin' racoon outta my garbage pail and dig it out then.

Here, its all I could get to without soiling my good clothes!

More? Fine then. But I'm putting a tarp down its muddy.

Now that is before I swapped in the post-pump larger filter kit from Go Westy. I wanted the original (but new) square filter I had on hand to catch any assembly BS when I fired it up. (BTW that pump is not hooked up downstream in that picture, don't hurt your eyes trying to figure it out, thats the shipping protection on the exit tube).
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

Couple things.

First about clamps. I read the debates and then just stuck with the originals.

Why?

Because engine patina is the next thing.

Actually its because they were not rusty at all and I really liked the shape of them with the fully rounded edges, check it:

I also decided to slip a little gasket material in between the EGR valve and the air distribution box. The EGR is long gone on my van and I want to eliminate any potential vacuum source.

Here is some gratuitous gas tank porn for y'all

Oh yeah.
_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Buggeee]

What else, what else.

Oh yes the exhaust. So the heater boxes actually checked out just fine to me. So I got a cheapo Empi faux merge muffler to throw on there for the neighbors, knowing full well I'll be pulling it off to sandblast and ceramic paint in the spring.

But here's the catch.

One side the bolts are rusted in there. Check.

But the other side the bolts are cracked off and the flanges are welded together.

Mother Effer PO. Dang, drop a dolla on her wouldja?

I stared at this for a while and then got out the grinder, going in from the rear.

On the driver's side I goofed up the flange a bit with the sawzall so I had to bust out the MIG.

Now both sides are ready.

Bolt her up.

Stupid Empi. Stupid PO welded on trailer hitch reinforcement (which I actually like )

So, a little floor jack handle fab.

Good to go.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764

[Vanagon Nut]

[Buggeee]

Old Timey Airheads are notoriously frugal.

So please, I'm going to splurge a bit

Knowing full well that I had at least four or five strands of throttle cable left I went ahead and replaced this anyway.

_________________
1966 Sportsmobile Camper https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
72 Super Duper http://www.thesamba.com/vw/forum/viewtopic.php?t=672387
(adopted out) 61 Turkis Pile https://www.thesamba.com/vw/forum/viewtopic.php?t=728764