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1981 (@wileythewesty) TDI conversion, from ground up
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charleslabri
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PostPosted: Sun Sep 13, 2020 6:53 am    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Finishing off that door work this weekend. My brother in law came over to help. Paining is so COVID friendly because you gotta wear marsh’s.

Planning on getting final base/clear on the doors and body today. Here are a few pics from yesterday
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charleslabri
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PostPosted: Sun Sep 13, 2020 7:01 am    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Forgot to mention, here are some pics of the slider. Looks like someone went on it with a baseball bat on the rear lower panel.
Hard to tell here, but it’s BAD.

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I couldn’t find anyone who could get an old model door out to me reasonably, so I’ll just work with what I’ve got.

Metal hammering was impossible because the internal braces were in the way. So I flayed them out to get my hammer and weights in there.

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I hit on it for about an hour. Here’s were I ended:
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On to fiberglass
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charleslabri
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PostPosted: Sun Sep 20, 2020 6:53 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

(insert-- pics from my previous post of the doors finished:)
Believe it or not, that trashed door from the previous post looks all beautiful now. It turned out great. Like they say, its all in the prep.

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painted the body this weekend with my brother in law. The dude is a champ, drove up from SLO to Tahoe to help out two weekends in a row. Beast. Couldnt have done it without him.
He restored a 68 bug recently and paint was on his mind.

We pushed Ol' Wiley over to the front of the shop

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def had a lot of cars honk and double take.

after prep work (major body work and block sanding done previous weekend)
1. 400 sand the primer
2. Hand feel every damned square inch
3. Air compressor blow
4. Acetone wipe

then we set up the booth

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and loaded him in

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wet the floor to keep dust down
and ran the tac cloth over everything

Then we painted.. 2 coats base, and 2 coats clear satin

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Weekend before we had issues with the offgassing of the doors making folks upset in the shop, so we opted to use their industrial heater Wink size of a room. Could have fit the van in there, but they needed to keep it at 400 degrees. So we heated up the room, propped the door open a bit to get the outer room to ~115F and let it sit for an hour. We then turned the heater off and let it sit in the room over night- yielded great results, cured perfect.

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Pushed it back to my place.. and now she rests (under a cover so these damned pine trees dont pee sap all over the new paintjob)

All in all, great weekend, heroics from my bro in law for sure.
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jokeraus
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PostPosted: Mon Sep 21, 2020 6:12 am    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Looks great and love the color. Prep is a bitch but all worth it in the end.
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PostPosted: Mon Sep 21, 2020 6:18 am    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

That's an awesome color. The paint job looks great.
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charleslabri
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PostPosted: Thu Oct 01, 2020 1:57 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Been busy on the vanagon, but not posting, so heres a bit on whats done lately after the paint:

I prepped the pop top by power washing, lightly sanding everything.. doing some fiberglass repair and powdercoating ALL the hardware.
I used interlux 1 part primer and the top coat with a matte (1:1 ratio used here) finish. Turned out really nice. I sprayed it on with a 1:4 nozzle around 50PSI.
Im sure Ill get some serious flame for painting it black, but you know what. I like it.. and i run really cold anyway.

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Next i scuffed my new paint all over the interior and laid down two coats of lizard skin sound insulator and two coats of ceramic insulator:

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Finally.... I put down bedliner on the kick panels to add some rigidity to the lower:

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Next up i am going to flip the pop top and do lizard skin there and put some marine fabric down inside that. Should turn out nice. Solo moving the pop top is a real biatch Wink
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charleslabri
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PostPosted: Thu Oct 08, 2020 1:29 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

been doing some work on planning the water lines and such. Here is my fan shroud and the new fan I am running with a PWM controller Its a deralle 11" fan (in case youre windering). Should pump up the airflow and keep a moderate speed rather than a notched speed.

post-powder
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pre-powder
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Also I fixed up and powdercoated the H bar and added those repairs in to keep the internal bar from severing-- thanks all for this one, I was about to drop it into powdercoating and read the fix, 15m on the welder got me a much better H bar.

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charleslabri
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PostPosted: Fri Oct 16, 2020 6:33 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Ive been busy working on shoring up my doors the last bit.

First off, i took all my door hardware that was rotted looking or whatever and sandblasted/powdercoated it. It looks killer with the black on the new green paint. Additionally I added hushmat to the doors- I had a bunch of the stuff laying around so why not.

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I also have been using tef-gel as a recommendation from (@markward i believe somewhere) on all the screws that i put in to prevent seizing down the road. Stuff goes on like a thick glue. I am sure that tef-gel has some sort of loctite properties as well- its thick enough.

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Additionally i dropped one of the westfalia logos on the luggage rack, it looks really nice in silver. Im not going for stock, but the black/silver combo is purdy.

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All the door hardware being powdercoated lends me to think about how i want to lubricate all the little things. I ordered some moly/lithium base grease to use in the slider channel, but there are so many other smaller areas (say the slider door swing mechanism) that need some sort of lube. So what I have done is go out on a limb and use some rifle lubricant- its pretty high end stuff. I had listened to a podcast about it recently and i think its going to be an epic lube on all these small areas like latches and such that need something to keep em moving. The dude that makes it (for guns, mind you) is a tribologist and has built this specifically for high use metal on metal extreme conditions. Well see how it holds up. Stuffs called cherrybalmz

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charleslabri
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PostPosted: Sun Oct 18, 2020 3:15 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Funny how sometimes you are just working away like a slave to the vanagon and seem to have no progress to show.
Other days, you make monumental changes.


Today I slapped the rear decal on to match the front one. Thanks to previous thread somewhere where someone threw some measurements down. Basically its about 3/4" from the top of the lower bevel, and about 4" from the left edge.

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Next I got my doors on- wow that feels nice. I ran the new weatherstripping all around each of the front doors using the 3m black seam sealer- watch out that stuff is extremely hazardous to paint. I got a little on the body and it dont want to come off.
I also added that hushmat I had laying around to all three the doors.

Lastly i added a new weather bead to the rear slider cover.

Not sure what do do yet on the slider grease/lubrication. I did get some moly/lithium grease, but folks seem to have mixed experiences on what to put down. Ill likely use that on the rear slider spot, and then something else other places. Dont want rust to build up with that metal on metal exposed to the elements.

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Still waiting on my transaxle back from matt steedle and the engine from greg @ boxeer in nashville area
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charleslabri
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PostPosted: Wed Oct 28, 2020 8:33 am    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Matt Steedle sent me completion pics of the trans today. Yay!
GT 3/4 straight cut @gears (mating to the boxeer, so really excited about these)
New r/p REM polished
New sliders
Weddle hub
New reverse gear
Peloquin TBD
Steel cages bearings all around
4th oil plate
Folts gear carrier
New input shaft

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charleslabri
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PostPosted: Thu Oct 29, 2020 3:27 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

Look what the cat dragged in:


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That one of Greg's (boxeer) TDI kits? Sure looks like it
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charleslabri
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PostPosted: Sun Nov 01, 2020 2:06 pm    Post subject: Re: 1981 (@wileythewesty) Vanagon Airhead 2.0 FI. Build Log Reply with quote

My dad came up this weekend and helped out with a few things, it was rad.
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Things completed:
1. Installed Helicoils on the rear hatch because the damned thing had to be drilled out due to radical trash/rust in there
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2. Installed the SS coolant lines front to back and the groovy mount brackets that thesamba queued me into
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3. Installed the T3 sway bar with the HD endlinks
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4. Moved the brake lines out of the master-cylinder and redrilled their exits to the floor (plus the obvious bleed of the system) to install the radiator + the 11" derale fan on there
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(pic is pre-powdercoat and final mount)
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5. Lastly, installed hullliner on the pop top- first bit of interior finish, that was satisfying
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charleslabri
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PostPosted: Sat Nov 14, 2020 4:02 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

This morning I sliced 10mm off the input shaft of the transaxle and added a slight chamfer for the boxeer engine.

Based on another thread I was inquiring on, seems that the divot in the end of the input shaft is non-essential.

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Next up i mounted the rear hatch solo. What a crap job that is to do alone. I still cant get the adjustment right, i think ill have to phone-a-friend.

The old hinge attachment inserts was completely rusted out, so I am using some felt gasket from local auto supply and a bit of butyl mastic to keep the water out under that.

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erste
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PostPosted: Sat Nov 14, 2020 5:14 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

Awesome progress dude!!
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PostPosted: Sat Nov 14, 2020 11:21 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

Powdercoat door hardware looks great. Was thinking of spraying the hardware on my build but I think you've inspired me to get it all baked properly.

Great build, excited to see the final result
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PostPosted: Sun Nov 15, 2020 9:35 am    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

Above you picture brake lines which appear to have brass compression fittings. They are fine for emergency repairs, but I would ditch them. Look at AN tube nuts. They look similar, but the tubes have a 37 degree flare that seats on an AN splice. They are rated for the pressure a brake hydraulic system could see in a panic stop. Going to be a nice van.
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PostPosted: Sun Nov 15, 2020 2:31 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

^^. Great catch Mark.

charleslabri Please advise if you don't want me posting images here but fwiw, for future reference re: the 2.0 TDI install, here's what I cut off the Vanagon gas transmission input shaft on two different ABA swaps, each using a KEP adaptor plate.

Though a moot point, input shaft cut on 15º install was done an air cooled transmission, input shaft cut on 50º done on WBX transmission:

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charleslabri
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PostPosted: Sat Nov 21, 2020 10:48 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

MarkWard wrote:
Above you picture brake lines which appear to have brass compression fittings. They are fine for emergency repairs, but I would ditch them. Look at AN tube nuts. They look similar, but the tubes have a 37 degree flare that seats on an AN splice. They are rated for the pressure a brake hydraulic system could see in a panic stop. Going to be a nice van.


noted, ill make the change. thanks for the callout
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charleslabri
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PostPosted: Sat Nov 21, 2020 10:52 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

Vanagon Nut wrote:
^^. Great catch Mark.

charleslabri Please advise if you don't want me posting images here but fwiw, for future reference re: the 2.0 TDI install, here's what I cut off the Vanagon gas transmission input shaft on two different ABA swaps, each using a KEP adaptor plate.

Though a moot point, input shaft cut on 15º install was done an air cooled transmission, input shaft cut on 50º done on WBX transmission:

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Interesting catch here. I did a sort of `plastigauge` test today when mating the transaxle to the engine (pics to follow). I used some blue painters tape on the input shaft to see how far the shaft went into the pilot bearing when mating. I got about 3/4" or so. I had a friend who is a volkswagon mechanic of some 40 years inspect the mate. He was really concerned, but after seeing the tape trick said hed be confident that im not going to have issues with my 10mm cut.

I am helping Greg build a manual for folks who buy his kit so that all these details are hashed out in the finest detail.
Id say that anywhere from 9mm(maybe even less in your case here)-10mm would be sufficient for the gasser input shaft cut.
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charleslabri
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PostPosted: Sat Nov 21, 2020 11:12 pm    Post subject: Re: 1981 (@wileythewesty) TDI conversion, from ground up Reply with quote

So I finally have all the stars aligned to begin some of the fun work.

I pulled the boxeer engine out of the crate and hoisted it up in the metal shop. A number of the welders came over and whistled at the quality of gregs SS mounts.

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then i brought the shiney transaxle from matt steedle over and had the two get a look at each other

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then I mated em. It was a little tough to mate them since i have the peloqion diff in the trans so i couldnt move the axles by hand. So i ended up calling a vw mechanic bud over to help. We used a 19mm 12 point socket to slowly turn the engine over as we brought the trans to the clutch with the trans in gear so to match the splines and allow the input shaft to seat into the pilot bearing.

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We did a lot of measuring of the depth of the input shaft to the splines and how the pilot bearing would connect with the input shaft.
He was super concerned about a few things:
1. the pilot bearing being too tight on the input shaft and causing issues
2. the input shaft being too long (or short) and causing either the input shaft to punch through to the crank (too long) or the input shaft being too short and not mating well with the pilot bearing and causing premature wear and a failed pilto bearing.
we did a sort of plastigauge using painters tape on the input shaft to see how much fit on the pilot bearing we had once they mated. It was sufficient to get a good fit in the pilot bearing (yes its a bearing here, not a bushing) and not cause premature rattle/wear.
Tomorrow i am going to do a test fit. I think im going to have to do some mods on my firewall due to the aircooled trans sitting a bit further forward in the van. Ill update manana.
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