New owner of '85 camper - Chewy

[danielheff]

Hi Vanagon Samba crew, I'm Daniel and this is my family's new van. Its a 1985 Vanagon GL full camper with an EJ22 kennedy conversion. It was previously owned by user Colorado Yeti and I couldn't be more grateful that he's allowed me to pester him with questions about the van. It's very rare to get and answer to the "what was the PO thinking?!" question. I'm very lucky that he took great care of the van and wrenched on it himself so knows it inside and out. I didn't buy it directly from him but there was an owner or two in between us for the last year and a half.

I have a '70 squareback that I've replaced everything that moves on myself. There's no mechanical parts on it from when I bought it except maybe the steering shaft. This van doesn't need that kind of attention but I took what I learned on that car and tore into it almost on day one.

This is the story of one thing leading to another and doing my best to not keep track of how much I'm spending.

Here it is the day of purchase:

The most obvious issues were the transaxle leaking (pouring) oil, the clutch pedal going completely to the floor to barely shift, and the brakes needing love.

Transaxle out!

What I found, besides the leaking drive flanges, was that the pilot bearing that sits in the Kennedy flywheel was destroyed. Only the outer bits of the housing remained. This allowed the input shaft to move around a lot more than it should, breaking the throw out bearing guide sleeve, and the seal on the front of the transaxle. Thats why it was able to pour gear oil from the bell housing. I was actually relieved to find this since I knew trans needed a rebuild, but I was hoping it wasn't the engine rear main seal.

It got a full refresh, I don't know all the technical bits about the sliders and bushings that got beefed up and replaced, but I chose to add a Peloquin diff and a .78 4th gear. Keeping the stock 4.86 r&p. I also added a remote breather in case I ever cross some water. Just tapped the stock vent hole for a 1/8" barbed fitting, added a fuel line and breather zip tied up above the trans. I know other things like wheel bearings aren't water tight, but just something to do while it's apart since I'll never drill that hole once it's built.

New trans installed with fresh German axle assemblies. I used the Kennedy pressure plate and the clutch and pilot bearing that they include in the kit. Their clutch plate is a Sachs made in Mexico. I have a Luk one on hand for whenever I burn through this clutch.

No photos of this part but I also replaced the rear brake shoes, springs, cylinders and drums. I also replaced the drivers side wheel bearings because there was noticeable play (12 o'clock and 6). I made sure the nut was torqued properly but there was still play. I replaced the bearings, reassembled, torqued, still play. Dangit. Ok double check the stub axle. It fits nice and snug into the inner race of the bearings. Since it must be the wheel bearing housing I ordered one from someone in the classifieds, supposedly a good used one. I installed it with new bearings and seals. Put everything back together, still play! Might even be worse. If I had better measuring instruments I might have been able to tell the housing was ovaled out, but oh well. I'm leaving it for now, everything is moving properly and not heating up. Should last until I buy some of the Burley billet housings.

The clutch pedal and pin were very worn. I followed the instructions on here for removing the pedal without tearing apart the dash. I'll say that was one of the hardest amateur mechanic projects I've ever done. Laying upside down, balancing all the parts and reassembling really tweaked my back and cut up my hands. I don't want to do that ever again. Welded, redrilled, lubricated and reinstalled.

Next up is the auxiliary batteries. It had a battery under the drivers seat and an analog setup to charge it, but wasn't enough juice to run the fridge very long. TF49. I added the gowesty 50ah battery under the drivers seat since it fits so well, and a 100ah renogy lifepo4 in the closet.The Renogy MPPT and a bluesea fuse panel mounted behind the drivers seat. 150ah powered the fridge, occasional radio and phone charge for 3 days and used about 60% of the battery.

Right around when I became the owner of this van I bought a 3d printer for my shop and started to learn some fusion 360. I made some somewhat OEM looking speaker covers for some aftermarket speakers that were installed.

On the first road trip the usb plug on the aftermarket head unit fell apart so I'm trying out the Continental unit. It's basic but so far so good. I have it wired to the AUX battery.

Since the MPPT can charge the house batteries from the alternator AND solar, might as well utilize that feature and install a panel. I got the whole setup from Andrew at Campergy and am beyond thrilled with it. The brackets, panel and wiring all work together seamlessly and fits flush into the luggage rack. Install was very straightforward with clear instructions. So far testing the solar charging with the fridge running, I use about 10% of the battery per day.

The van already had a Fan-Tastic fan bolted to the original roof vent and I added some roof rack bars to carry surfboards. This extra weight was definitely noticeable when trying to pop the top so I also added the struts from Gowesty. This makes a big difference opening and balances the pop top perfectly to tuck in the tent before closing.

Speaking of surf, rinsing off afterwards is really nice. I followed most of the process laid out in this post by user "kourt" in this post: https://www.thesamba.com/vw/forum/viewtopic.php?p=8327610

I put my pump in the rear closet next to the battery and routed the connection out the back.

I printed some sleeves for screws I had to make shelf pins that will hold a false bottom for the closet and cover up the battery and the pump.

Sorry to the purists, but I've already drilled so many holes in this van and other vehicles, so one or two more wont hurt. Especially to gain an amazing feature.
I added the quick connect port for the water and the switch for the pump to the bottom of the rear cabinet. Its low enough that it doesn't take up any of the closet space and all the hose and wires are in that empty space to the left of the engine lid. The clear plastic is to try to divert the small bit of water that inevitably drips after disconnecting. It's probably 1/2 oz but I just don't want it to soak into the wood of the cabinet.

I also stripped and repainted the wheels. These are Fuchs from an audi 5000 which Colorado Yeti explains his process here: https://www.thesamba.com/vw/forum/viewtopic.php?t=736250&highlight=
I preferred the look of the silver outer rim and solid black interior. It matches the Fuchs on my 944. I also broke a couple of his clever center cap adapters in the process, so I designed, 3d printed and painted some ones that look more like the original Audi ones, but with the appropriate VW logo. The paint is VHT satin black. It looks very similar to the Porsche Fuchs.

Here's the van all together as it currently is.

Thank you all for the many posts that I've been able to reference to get me to this point. It's been fun dialing in this van to meet my families needs.
Again a huge thank you and nothing but respect for Colorado Yeti who laid the foundation for all of this.

-Daniel
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'70 Squareback 1835cc
'85 Vanagon GL Camper, EJ22, Peloquin Diff, Burley rear disc brakes, SC big front brakes, Espar D2L, 250ah Lifepo4
'85.5 944 NA

[valvecovergasket]

looking fantastic
really like those wheels as well, nice work

[jlrftype7]

Great work all around….
Speaking of your ‘70 Squareback….
I never got to own a Squareback, I went to look at one and the guy had a much nicer ‘67 Fastback next to the pretty rusty earlier Squareback. I think it was a ‘66..
So I bought the Fastback…
I really like the Shower Connector in the back of your Cabinet too.
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'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto

[dobryan]

Great work!
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Dave O
'87 Westy w/ 2010 Subaru EJ25 (Vanaru) 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

[jimf909]

Holy Toledo, that would've taken me three years and I would have skipped the wheels. Nice work.
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- Jim

[danielheff]

Thanks for the support! Mid-June was when I started working on it. Don't worry it hasn't been all bloody knuckles, we've taken it camping a few times already and my kids will go eat dinner in it even in our driveway.

Copper doesn't know exactly where to sit since he usually sticks his head out the window of my Square or truck, but he'll figure it out. The next major project is the AC, which he'll appreciate as much as my kids.

_________________
'70 Squareback 1835cc
'85 Vanagon GL Camper, EJ22, Peloquin Diff, Burley rear disc brakes, SC big front brakes, Espar D2L, 250ah Lifepo4
'85.5 944 NA

[snoop]

Yes, top work. May the adventures ahead be matched in joy by the effort to make them happen.
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87 Westy Camper

[Colorado Yeti]

This warms the cockles of my Wookie heart. The saga of Chewey continues. I would like to see it again if I come out to San Diego. Keep the fires burning.

[danielheff]

Thanks everyone for the support. Looking for some suspension advice without starting a new thread.

The shocks and spring setup currently is what I believe are stock springs, rears I just put in the XHD Bilstein, front has Koni's. We have a pretty bad lean to the drivers side, an unusual amount in the front.

Front
16.75 - 17.75

16.50 - 17.125
Rear

Again this is a full camper and I keep water in the tank most times. I'd love to be at the ~17.75" all the way around. I definitely want to put in a fresh set of springs, but am struggling between the Gowesty 0" lift and the Schwenk springs.
For damping I'm thinking about going with the XHD Bilsteins from GW.

Anybody have a similar configuration that they like their setup or recommendations?
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'70 Squareback 1835cc
'85 Vanagon GL Camper, EJ22, Peloquin Diff, Burley rear disc brakes, SC big front brakes, Espar D2L, 250ah Lifepo4
'85.5 944 NA

[snoop]

I can certainly endorse the shocks presented by Nate and Nancy Baldwin in their 'Van Tour' video:

https://www.youtube.com/watch?v=d0kzJvIQXXY

Model #'s are in the description underneath the video, but here they are too:

Front: Rancho RS999136

Rear: Bilstein 25-176230

I'd choose Schwenk springs

Christopher at T3 Technique can advise you on what dimension shims to add to your driver's side suspension to level out Chewy.
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87 Westy Camper

[SCM]

Van looks great and I love how the wheels came out.

What kind of awning is that?
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'91 Westfalia GL Automatic (GTA "Turbo" Rebuild w/Peloquin) and 2.3L GoWesty Engine

[danielheff]

[danielheff]

Hello all, I wanted to post an update on a heater project I've almost completed in hopes that it may help someone else considering doing this. Maybe I'll use enough keywords that it will show up in searches rather than starting its on thread.

I recently installed the Espar Airtronic S2 D2L heater in my van to help make it nice and cozy on cold camping nights. I chose this over the Chinese diesel heater mainly because of my risk tolerance.

The main hurdle was the fuel. I chose to use diesel because it's about twice as efficient as the gasoline version and I liked the idea that I'd never run out of the fuel needed for the engine because of our heater. Even harder to decide was where to put the tank. I really don't like the idea of a diesel tank inside the cabin since the caps are vented. I ended up buying a "Scepter Portable Fuel Tank" 3 Gallon from Bass Pro online. It's meant to be a fuel tank under a seat and has the pickup already built in rather than repurposing a jerry can or those milk jugs on amazon sold as diesel tanks. Any negative review on this tank was about the pickup tube coming loose, so before fulling it I opened it up and put hose clamps on the pickup tube and extra sealant around the pickup/indicator plate.

Then I mounted this in my spare tire location, first with a ratchet strap holding it in place but now just made a small tray with some 1 1/4" aluminum angle riveted to the tray. This with a rubber strap through the handle holds it really securely. Also this storage location is at an angle so I have the pickup end on the downhill side.

To connect the tank to the system I used outboard engine connectors from West Marine, I believe they were meant for a Yamaha outboard, but as long as you get a matching set it'll be fine. My line is long enough to fill up the tank in front of the van, but if I needed to disconnect the line I didn't want to deal with priming the system again.

The heater lives under my bench and blows out where the stock heater was and I cobbled together a piece of wood to fill the original area and mount the vent. It's close to the body on the inside but it breathes just fine.

I also added a propane & CO detector while I was cutting holes in things for an added layer of safety.

_________________
'70 Squareback 1835cc
'85 Vanagon GL Camper, EJ22, Peloquin Diff, Burley rear disc brakes, SC big front brakes, Espar D2L, 250ah Lifepo4
'85.5 944 NA

[zephyrj]

Van looks great! I also run Audi Fuchs since 80s Audis are my main jam, but never figured out a center cap solution so have been running capless. Would you be willing to print another set or share the file?

[danielheff]

[mtnhome]

The van's really looking great! Nice work. I like those wheels too but never found a set. It was easier finding CLK's than those!

Interested in how you tied both the 50ah and 100ah batteries into the Renogy DCC30.
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'84 Westy, '93 Subaru ej22 and Subarugears 5speed
Build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=763098&highlight=

[danielheff]

Thanks! It's been fun to work on.