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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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 Posted: Tue Aug 16, 2022 6:51 pm Post subject: Another build - 1987 Westy |
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Thought I would share another build on "saving" a van that was in rough condition.
My father purchased this vehicle so we can have a "project" to work on. He already owns an 86 Westy that I have helped him build. We are both very familiar with Vanagons as we have owned numerous between the both of us.
Van was purchased in the state of NY and shipped to Oregon. 
Previous owner gutted the entire vehicle - interior and exterior. Project is near completion and will post pics/process as I go through some of the pictures.
Here is how it started.
Gutted from the interior, but came with the complete interior. Original 2.1 engine taken out and sitting inside.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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campism
Samba Member
Joined: September 07, 2007
Posts: 4361
Location: Richmond VA
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| Posted: Wed Aug 17, 2022 4:32 am Post subject: Re: Another build - 1987 Westy |
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Looks like a challenging project. Keep us posted and good luck!
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'87 Westy in Wolfram Grey Metallic |
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DuncanS
Samba Member
Joined: October 17, 2013
Posts: 4003
Location: New Hampshire
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| Posted: Wed Aug 17, 2022 5:54 am Post subject: Re: Another build - 1987 Westy |
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It's a blank stretched and gessoed canvas. Go paint the next Mona Lisa.
Duncan |
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joetiger 
Samba Member
Joined: January 27, 2005
Posts: 4982
Location: denver
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| Posted: Wed Aug 17, 2022 5:57 am Post subject: Re: Another build - 1987 Westy |
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Joe T.
'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'04 GTI 1.8T
"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron
"Still, it's good to be afield."--VWagabond
Available Now! Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present
www.josephtrussell.com |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Aug 17, 2022 6:33 pm Post subject: Re: Another build - 1987 Westy |
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No surprise here, common rust spots. Several more were found later as windows were removed and body work started.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Sat Aug 20, 2022 8:16 am Post subject: Re: Another build - 1987 Westy |
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Since the interior was already gutted it was a good opportunity to add sound deadener to the interior panels and fix the some common rust behind the sink.
At the same time while debating if I should rebuild the original 2.1 that was sitting on the floor board or go with a conversion. I came up on a good donor vehicle (2003 Legacy) in a recent accident. Decided to go this route instead.
Besides the condition of the 2.1 was unknown.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Sat Aug 20, 2022 9:46 am Post subject: Re: Another build - 1987 Westy |
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I dont know much about body work, but have a good friend who works at a body shop and for trade work he did all the prep work.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Aug 24, 2022 9:23 am Post subject: Re: Another build - 1987 Westy |
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While body work is getting done. I started working on pulling motor and harness from donor subaru.
Also decided to go with small car bellhousing, headers and engine mount. I used the same setup on my dads conversion and has worked well (over 40k-50k on that conversion).
Body on this westy had 125k miles and tranny plug shows minimal wear.
Preping engine bay for paint as well.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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valvecovergasket
Samba Member
Joined: October 10, 2018
Posts: 1385
Location: pnw
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| Posted: Wed Aug 24, 2022 10:52 am Post subject: Re: Another build - 1987 Westy |
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next level west coast difficulty starting with an east coast van 
in for more updates!
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MegaSquirt resource - SpitfireEFI.com
'83 tdi westy - swap thread |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Aug 24, 2022 11:19 am Post subject: Re: Another build - 1987 Westy |
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| valvecovergasket wrote: |
next level west coast difficulty starting with an east coast van
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It had factory underspray - so there was minimal rust on underside.
After several weeks, I brought back home from the paint booth (final cut and buff not done yet)
Also removed the top during body work prep and paint, and cleaned it while it was removed, a new tent was also installed.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Nov 30, 2022 11:03 am Post subject: Re: Another build - 1987 Westy |
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I haven't updated this thread in a while. Thought I would continue to post some of the previous progress pics as I go through them.
Installed new fuel tank, upper control arm bushings - LEMFOERDER brand- I had a set one hand from a previous build that I ended up using the GW kit on that one. And as I was purchasing parts for the subaru conversion, I came across and article on BurleyMotor sports website were they DONT recommend urethane bushing on upper control arms for some reason.
(https://burleymotorsports.net/technical-articles/the-making-of-burley-bushings/)
I personally have not had any issues with urethane bushings, but since I already had some lemfoerders on hand I just went with those.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project
Last edited by skemems on Wed Nov 30, 2022 11:08 am; edited 1 time in total |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Nov 30, 2022 11:05 am Post subject: Re: Another build - 1987 Westy |
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Next up was moving forward with suby 2.5 engine install.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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vino de vano
Samba Member
Joined: September 10, 2016
Posts: 355
Location: columbia gorge
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| Posted: Wed Nov 30, 2022 2:56 pm Post subject: Re: Another build - 1987 Westy |
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Looking goooood
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what a long strange trip it's been |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 8494
Location: Western WA
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| Posted: Wed Nov 30, 2022 3:44 pm Post subject: Re: Another build - 1987 Westy |
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How about the clutch pedal mod for that smallcar bellhousing?
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two vans:'90 Westy with '07 EJ25 '12 longblock, 3-knobber, F&R Peloquin TDBs, pressure oiled transaxle mainshaft & pinion bearing, with cooler & filtration. 150Ah LiFePO
'87 Tintop with 47k, '12 SmallCar EJ25, Peloquin front
....KTMs, GasGas, and a Stumpjumper |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Wed Nov 30, 2022 5:46 pm Post subject: Re: Another build - 1987 Westy |
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| Sodo wrote: |
| How about the clutch pedal mod for that smallcar bellhousing? |
I just used the clutch spacer smallcar provides, its been working fine and personally dont mind the clutch feel.
Did you ever get your issue resolved? I remember your post below that it still overextended the slave.
(https://www.thesamba.com/vw/forum/viewtopic.php?t=770212&postdays=0&postorder=asc&start=6)
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 8494
Location: Western WA
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| Posted: Wed Nov 30, 2022 11:36 pm Post subject: Re: Another build - 1987 Westy |
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| skemems wrote: |
| Sodo wrote: |
| How about the clutch pedal mod for that smallcar bellhousing? |
I just used the clutch spacer smallcar provides, its been working fine and personally dont mind the clutch feel.
Did you ever get your issue resolved? I remember your post below that it still overextended the slave.
(https://www.thesamba.com/vw/forum/viewtopic.php?t=770212&postdays=0&postorder=asc&start=6) |
I think it overextended the slave because the clutch disc was new and the pressure-plate fingers start 'farther in' which means the slave 'start point' is 'farther out'. And then a proper 'amount' of fluid can over-extend the slave.
Whereas on my other van, the clutch disc was 40,000 miles old.
So the old clutch disc did not need the spacer.
But on the other van (new clutch) the new disc is thicker so it needs the spacer.
You can bet I'm putting the spacer on the old van now!
Does this make sense?
The spacer still limits the amount of fluid.
But the pedal modulates much better within that stroke.
If your clutch pedal clevis pin is worn, you have to address that someday and can drill a new hole at that time?
SOMEDAY I will measure the volumes and see if there is a pedal-pivot offset that truly eliminates the spacer.
And that would result in the softest, smoothest clutch action there is.👍🏽🙏🏽
Here is a related problem I worked on with someone else, but I can't recall who it was or what forum.
I think the guy installed a disc that was too thick and it caused the slave to over-extend.
To make sense of this you have to 'read it in the sequence' of the circled numbers.
If the disc is too thick, it can set the diaphagm spring on the pressure plate too far 'down' which in turn causes the slave start position to be too far extended.
Where a normal amount of fluid drives the slave past its limit.
So the takeaway here is, for the concentric slave/bearing, do NOT use a disc that's too thick.
What we need is a "pressure plate finger depth measurement" that ensures the slave won't be over-extended.
I hope this is understood.
It's not easy to type this problem with clarity.
The key is --- the slave bearing riding on the pressure plate fingers is 'the start point' of the slave cylinder extension.
If it starts too far extended, it will be driven past the stops.
_________________
two vans:'90 Westy with '07 EJ25 '12 longblock, 3-knobber, F&R Peloquin TDBs, pressure oiled transaxle mainshaft & pinion bearing, with cooler & filtration. 150Ah LiFePO
'87 Tintop with 47k, '12 SmallCar EJ25, Peloquin front
....KTMs, GasGas, and a Stumpjumper |
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jimf909
Samba Member
Joined: April 03, 2014
Posts: 6712
Location: WA/ID
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| Posted: Thu Dec 01, 2022 6:19 am Post subject: Re: Another build - 1987 Westy |
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| skemems wrote: |
| I haven't updated this thread in a while. |
Holy Toledo, this looks like a fun project. Am I seeing correctly that this is a total repaint from Pastel White to Flash Silver Metallic? Savannah Beige Metallic? Something else?
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- Jim
| Abscate wrote: |
Do not get killed, do not kill others.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Thu Dec 01, 2022 3:34 pm Post subject: Re: Another build - 1987 Westy |
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| Sodo wrote: |
Does this make sense?
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Completely, thanks.
| Sodo wrote: |
If your clutch pedal clevis pin is worn, you have to address that someday and can drill a new hole at that time?
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Yes thats the plan.
| Sodo wrote: |
SOMEDAY I will measure the volumes and see if there is a pedal-pivot offset that truly eliminates the spacer.
And that would result in the softest, smoothest clutch action there is.👍🏽🙏🏽
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Yes, let us know when you do. This allow to test the redrill of the clevis to ensure correct fluid volume.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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skemems
Samba Member
Joined: February 23, 2017
Posts: 153
Location: Portland
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| Posted: Thu Dec 01, 2022 3:38 pm Post subject: Re: Another build - 1987 Westy |
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| jimf909 wrote: |
| skemems wrote: |
| I haven't updated this thread in a while. |
Holy Toledo, this looks like a fun project. Am I seeing correctly that this is a total repaint from Pastel White to Flash Silver Metallic? Savannah Beige Metallic? Something else?
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Respray of original Flash Silver Metallic. When purchased it had primer, so I kept original color. Didn’t want to deal with respraying interior, plus I really like Flash Silver Metallic.
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87 VW Westfalia - EJ25
86 VW Westfalia - EJ22
85 VW Westfalia - WBX 2.1 project |
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DuncanS
Samba Member
Joined: October 17, 2013
Posts: 4003
Location: New Hampshire
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| Posted: Thu Dec 01, 2022 4:02 pm Post subject: Re: Another build - 1987 Westy |
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Had a Silver Flash. My favorite color.
Duncan |
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