1981 (@wileythewesty) TDI conversion, from ground up

[charleslabri]

oh my.
Evacuated out of south lake. First drive with the van was a 60 mile trip across west lake tahoe to Truckee where ive evacuated.

Got most stuff out. Lets hope this thing doesnt burn the town.

Thanks for all the help those of you who are assisting at evacuation centers and the firefighters working the fires!

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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[4Gears4Tires]

Just in time. I'm glad you got the van and bikes out!
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[charleslabri]

[charleslabri]

No pics here, but....

put all the windows in + new seals (thanks Dave at outwesty for the rear window!)

tightened up my shifting mechanism and put some loctite on there as it was getting loose

added heavy mechanical sheathing to any line or wire that was getting signs of rubbing while driving

put on the pop top struts (jeez, this really helps)

put on the pop top to cargo bay seal. I went with an OEM one (i think- flat lip on one side and a metal lined `mouth` with rubber seals inside) and it was pretty hard to fit over the lip. i used the 3m window rubber seal in there to keep it tight.. but this was more of a pain than expected.

been chasing down an issue with the metal filler neck not aligning properly with the body hole or else causing leaking. Ended up buying a plastic neck and conversion grommet instead. I have a thread about it.

Been driving the boxeer conversion around with Gregs new v2.2 tune, and checking levels, pushing it on passes, etc.
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[charleslabri]

Simple update here.. been working on getting my raspberry pi 4 dashboard working.
Im using the OBD python3 library on github.

Ive got the initial bluetooth connection made and some of the basic PIDs reading of the boxeer ECU.
More to come!

(ill def be open sourcing this and doing a writeup)
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[charleslabri]

I wanted to give a brief update as a few things have come along.

I know a lot of folks are interested in hearing about my experiences with the engine that i put in.

Ive got 2200 miles on the EA288 now, so i feel kinda got the hang of it.

Ill just bullet point my opinions here:

General: the engine feels great, starts up every time and has been issue free over the miles ive put on it. Of course i have done a LOT to the van other than the engine, which probably leads to the lack of issues.

Power Vs Mountains: When hitting passes (done CA89/88/49 a lot) the van never lacks power. i more manage the RPM over the engine- making sure i keep the RPM manageable while maintaining good momentum. Ive usually been the one passing other folks.

Starting/Temperatures: Ive had no issues with starting, though i have the upgraded starter. Ive run it in 25f to 100f weather, ran great all times.
Temps usually sit at 195f on the dot while driving. I can probably train my front rad fan down a bit. Intercooler temps are typically 160-250f.. i think i hit 260f on the intercooler once while hitting a grade in 100f+ outside temps. In the cold (below 50) it generally stays below 220f.
Lastly the turbo temp max ive seen is 1450, but i keep an eye on it and when im going up a pass i mark myself to not exceed 1400 or so. 2% the gas pedal will quickly take it from 1400 ->1100. I read somewhere that 1500f was around danger zone for a turbo.

Turbo Boost: ive never seen the turbo hit above 19.5. Id bet money that there is an artificial limiter in here in the ECU. I wouldnt generally say that im overwhelmed with the power or anything- it rides like id expect it to. My Tundra can kick ass in a way that this van cant, but the toyota is a completely different vehicle.


Support: Gregs a nice guy, but id generally say he isnt prepared for support. Most of my ability to install this engine by myself came from a smattering of other places- namely community. Id totally expect this engine install to have zero warranty. So if i get really broke down im on my own. I made a manual to help others with the install, but there were so many oddities with the installation that I am not sure if its generally valuable. If you buy one, be prepared to figure it out on your own. G will give hints and helpful tips, but youre going to be leaning on your own knowledge to make this happen- and its not plug and play.
Lastly, the ECU- G has done a good job at getting the ECU in a place where it runs well, though seems the power is slightly crippled (see boost notes). Most sensors seem to have been just removed and forgotten. Id imagine long-term this will be the issue. VW put sensors in the engine for a reason, and having the ECU not interact with valuable sensors is a really scary long term proposition.


Id imagine one of these days the engine will go kaput and ill not be able to get any good support on it and end up putting something else in the van which is more widely supported. In the meantime, its nice to drive a van that doesnt sweat to drive a bunny hill.
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[skemems]

I was following your build, thanks for update and review of the EA288.
Any pictures of the interior at all?
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project

[charleslabri]

[erste]

Really sweet build. Nice work!

[Zeitgeist 13]

Do you know which sensors aren't being used on Greg's engine?
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[charleslabri]

[charleslabri]

i recently ran across a pic from April 2020 when i was driving my vanagon around Coulterville, CA.

I nosed up the two to just marvel and the amount of damned work ive put into this thing. Dream to drive.

Feels good to have some visual, just for myself, to see how far ive come
_________________
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[charleslabri]

Most of 2022 I've been waylaid as I purchased a place in Nashville to spend half the year in.
Though some recent changes to the van warrant a post.

During the Oak Fire incident in Mariposa, I had to evacuate from my place. Unfortunately I was in Nashville. My brother, the loving soul, drove up from Ventura to Mariposa (approx 5h) to get the important things away from fire danger. I said to him on the phone, "please, brother, the only thing I need saved is the van". I had parked the van inside a 40x9' shipping container to keep the elements and mice from consuming it wholesale.

He was a good bro and went up to evac the van.
Unfortunately on exit from the shipping container managed to smack the engines oil pan on the lip of the container and caused quite an oil leak. He called me and asked, "Should I just drive it with an oil leak to Fresno where I am evacuating the stuff [at a friends house]?". "Noooooo" I replied. He had it towed.

When it got down to Fresno, some local neighbors were intrigued by the engine and a diesel mechanic and an aircraft mechanic decided to help me out and do the repair while I was stuck working in Nashville. John, the aircraft mechanic sort of made fun of the low clearance for the engine I have in the vanagon, but thought the conversion seemed cool to drive. So in exchange for some cash and a chance to drive, "a vanagon, which is a general piece of crap, but with a super cool engine which may prove to be cool." and "an insane level of attention to detail in this thing.... you did this yourself?".
The ground to engine clearance on a stock aircooled vanagon for this 15 degree engine conversion is .. 6.5-7". I could put a candybar under there and smashed the oil pan. He threw in to the convo that I should, "do a body lift and I can make you a skid plate.". I told him that I didnt think a body lift would be reasonable, I would support him building a skid plate and sending him the parts to do the lift.
I shipped him gobs and gobs of cash in the form of parts (new bushings, new UCAs, UCA spacers, Springs, shocks, spacers, ball joints and spacers + a new oil pan.
a few months later he called me back. Said the work was done.

I was prepping a snowbird exit from Nashville anyway, so I drove from Nash to Fresno in my truck. When I arrived, he blew my mind with the skid plate.
Though, unfortunately when I looked at the lift size i was... confused. I measured 16.5". I recall it was 17 with stock suspension. Turns out in the frenzy of fire evacuation, etc, etc I ordered carat springs from burley. Zomg- bummed- upset with myself- now I have 4 $400 pogo sticks. Burley dont take things back (who wants carat springs anyway). So I purchased some proper springs and installed them. Got me up to 19" all around.
The good side was that the skid plate was very nice. He welded a 1" extension onto my exhaust to bring it flush with the skid plate (see pic) and then did a nice cutout for the oil screw. The whole thing was pretty thick steel and we did a test by lifting the vanagon by the plate to ensure that I could smack something pretty hard and not damage the engine. Its honestly a work of craft.

Had a lift, so the rear springs took about 10m each, and the front springs took about 1h each. Didnt need to use a coil compressor since we had a floor jack and a 4' piece of 4x4 to compress.
After the proper springs installed my skid plate has 9.5" of clearance, and the engine a bit more than that under the plate.

For some reason my pic uploads arent working, so I will add those pics here when thesamba gets its head on again
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[charleslabri]

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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[charleslabri]

My lovely wife let me put the van in the living room to wrap things up.

I've been back into the dashboard, getting gauges and such working.

Yesterday I ran 5x 20 gauge wires front to back for some extra sensors. You really can never have enough. Initially I ran a CAT6 line for sensors and stupid me forgot that cat6 is solid core, so bad for automotive. I yanked that out and added real automotive wire.

Off those 6 wires ill run
- coolant temp wire, which comes off a Febi 01939 temp sensor on the block (Not sure why Greg removed the original G62 sensor there).
- Transaxle temp mounted on the flange just below the mount for the clutch action arm brace thing. Using a Dakota CHT that I had purchased for the aircooled head- i figure this should work out just fine
- Coolant level sensor (needs two wires) from the new coolant tank
- Alternator light

Total comes to 5 wires so I should have a single spare. I am going to junction them in the front and back so I can have consistent wiring colors (my good wire cuts were only 10').

I also fixed an old leak in the heater core up behind the dash. My original design brought the new silicone hoses right up to the heater core without the use of 90's. So this ended up in a stress leak on the cold side. Rectified with some brass 90s.

Last up I had installed my PWM fan controller backwards (battery in motor mount and motor on battery terminals) So I switched those and replaced the blown fuse. Still trying to figure out where Ill mount this under the dash.
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=

[ALIKA T3]

I would install better quality hose clamps especially in the dash, with a wider band too. These look very cheap...
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[Zeitgeist 13]

^^^especially on that silicone hose, which can be really slippery. I've seen those thinner screw clamps strip out numerous times.
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[charleslabri]

good call. will do
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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
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[4Gears4Tires]

[charleslabri]

I sneezed and they fell off.

Replaced

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An example of my labor in action:
https://www.instagram.com/wileythewesty/

My Build Thread:
https://www.thesamba.com/vw/forum/viewtopic.php?t=730525&highlight=