Rapidly approaching

My parts budget is coming close for the initial run through.  Ordered up the Bilstein shocks all around today.  Going to hold off a bit on the coil springs, at least until I have it on the road and can evaluate what I really want (or need).  I am sure the first time out will produce a list of needed items, so having a piece of the budget aside for avoiding that embarassing moment with the wife will be important.

I have plenty to do with the parts I have now.  Yesterday gave us an additional three inches of snow, and today an inch or two of rain has left everything a mess.

Weather better

Now do not get me wrong here, I do have a two car garage at my home.  It was built in the 40's for a much smaller breed of automobile.  And hence, the Vanagon is too tall for the doorway in its present state. There are plans to attend to this over the summer, but right now the garage is full of Harley's, a motorcycle lift, tool rollaways, lawn tractor, compressor, a couple double door commercial freezers, and a whole host of other assorted stuff.  A serious reduction in 'stuff' is coming, soon.

So given the 'fullness' of the garage, working on anything during winter is a pain in the ass.  When I do work on the vehicles, it is exposed to the elements.  This year has been particularly harsh, with all the snow, so work progresses slowly.

Remanufactured engine - will still leak.

Yesterday was one of those days that was warm enough to dry up the driveway and I was able to crawl under and do some more evaluating.  Not so happy with what I found.  There is a sway bar link missing - its just not there.  I found a piece of a coil spring on the drivers side rear suspension. And when I started doing a degreasing of the engine compartment, the van stalled when it got wet.  So adding to the list is a new set of coil springs (was contemplating anyway - maybe an inch lower), a sway bar link (which I found on the Samba classifieds), and tracking down the cause of the stall.  I have not done the tune up yet, so hopefully that will cure the issue, but knowing these vans, it is never that simple.

On the brighter side, under the grease I found an official VW tag for the engines remanufacture.  Seems this engine was replaced at some point in its life!  Does not really surprise me, they ALL need engine work at some point, but to find a remanufactured by VW was surprising.  I would tend to think that the breakdown either happened within warranty period, or a prior owner just used a dealership to service the van.

Put together a list and an order with GO WESTY to do rear brakes (drums, shoes, hardware, adjuster screws, wheel cylinders, stainless braid brake lines, wheel bearings and seals), to do front brakes (rotors, pads, stainless braid lines, bearings, seals, thrust washer, axle nuts) and to repair the leaking poptop vent.  Seems the plastic washers on the vent arms are missing (broken) and a source for a possible leak.

Will be ordering up some Bilstein shocks all around this week, and probably the coil springs.  Need to evaluate the bushings in the control arm, the strut (the washers rot away) and plan for those.  If I am going to disassemble for springs and shocks, I would be a fool not to take care of any dry rotted bushings while I am under there.

All in all, the van should ride fairly solid and smooth once these items are completed.  We are talking about a vehicle with the aerodynamics of a brick.  Expecting this van to slip through the air like a Lamborghini Countach is a bit far fetched, but I do not want to make it any worse than when it emerged from the factory.  The lowered center of gravity should help with some known issues, as will the wheel and tire upgrade.  Having a solid foundation in the suspension and its geometry necessary for a enjoyable vehicle. 

I know there are some out there who will balk at lowering the van.  And to that I would state that IF this was a syncro, I would definitely NOT lower.  Also, IF this van has a future in any off road environment, I would also not lower it.  However, since this van is being built as a road queen, with nearly all of the planned excursions being of the road way variety, I am going to lower it a bit for my preferences.  Also, if I had plans to do an engine swap, I would also consider another setup.  So right now, this is the way I am going. 

Also have a seamstress in the family, so she has bought some nice 2 inch foam product and material to make a bed topper.  Will be able to have it cleaned, and should make sleeping absolutely fantastic.

Itching

to get working on the van.

Wrong tires - cheapy passenger type.

Picked up another 8 hole Mercedes wheel for spare tire use.  If I am going to be mounting the spare on the pathfinder carrier on the rear hatch of the van, it should be at least decent looking.  Craigs list - Central Mass, $20.  Of course I will have to pay for the disposal of the old tire, but I guess its a small price to pay.

Got a new (used) spot blaster from my auto body friend. Had one years ago, lost it in the same move I lost 120 pounds of dead weight (the ex).  Still coming across things that I used to have.  Could be my whole roll away, and I would have still come out ahead.  Anyways, I digress, spot blaster and some new goggles to hit any rust spots inside the van while installing the sound deadener.

Same thought - visited an old friend at an auto body.  Last time I played with cars, Vari Prime was the cats meow as far as applying to raw steel.  Damn that stuff will kill you, quick.  Needed to get up to speed again on proper products to be working on the van.  The Harleys I have been working on on the past 8 - 10 years have all had professional paint jobs, so I have lost my edge with the current products.

Jim will be putting together a box of stuff for me to bring home and have ready for quick repairs - a nice high build primer, some paint, blending agent, clean up agents, DA paper, some blast media, etc.  Also picking up a couple inexpensive HVLP guns to do the job - one for primer, one for paint.

Still racking my brain for a name.  The van needs a name.  I feel that I want to incorporate some sort of reference to my grandparents, or specifically grandmother, who took me EVERYWHERE in her VW vans.  It was her willingness to share what she knew through those vans that got me hooked.  So I think its only appropriate.  I guess one day it will come to me.

Carpet kit has arrived!

My box from SewFine arrived yesterday.  Looking forward to having that chapter completed.  Looks horrible in there without the consistency of one flooring color.  Can't really justify doing it until I get some sound deadener down and make sure there are now rusty spots that need attention.

Spent some time with Chris from T3 Technique yesterday as well.  Wanted to order up the correct longer studs for the rear wheels, a conversion kit to put studs on the front wheels and a new set of lug nuts all around.  Consistent, correct fitment and never have to worry about it again.

Extreme winds overnight have dislodged a half dozen shingles on one of my dormers.  Still very windy, which leads me to question whether I want to be up on a 40 foot ladder to get to my roof.  Guess there will be no playing with the cars today.

First decent day yet this year

Got to play a bit today.  Been dying to dig in, but the 20 degree weather has put a damper on things.

Put the Mercedes wheels I got up in Vermont on the Vanagon.  Needed to do a trial fit, in order to establish the length of wheel studs I will need.  They went right on.  Given that these are an Italian aftermarket version of the venerable 15 x 7 in. Mercedes 8 hole alloy, the holes were already a large enough for the Vanagons rear studs and front lug bolts.  Need to get others though, as the seats do not match given the Vanagons concave seat and the Mercedes conical seat.  Already contacted Chris at T3 Technique for the right ones.

Also had to replace the bulb bases for the front side marker lights.  The design flaw allows moisture to get in and then sits there and rots out the connectors.  Found a pair of aftermarket ones at Bus Depot and they arrived today.  Got them in, soldered in new connectors and replaced the lenses.  Thinking about drilling a very small hole in the bottom of the lens to allow drainage, but jury is still out.

Remainder of the lighting all works except brake lights.  Need to tackle that tomorrow.  Brake switch is located near master cylinder under instrument panel cover.  Just going to replace it regardless of what I find.  Its a pressure switch, unlike more recent cars having an electrical switch.  If the switch is original, its far too old and will require more pressure to activate than a new one.  Will start there tomorrow.

Need to get some pictures going.

Also topped off tank today.  Learned that the vapor release setup on top of tank is leaking.  Common enough issue.  But now that the tank is full, I will need to wait to drop the tank and fix it.

Amassing more stuff

Few weeks ago I bought a set of 8 hole Mercedes wheels like the ones on my 94 E420 for the Vanagon.  The pattern is the same 5x112mm, just have to be concerned with the offset.  Now I know the 15x6.5 needs a spacer of about 10mm, but the 7 inch wide ones have a different offset.  Still need to try them. They were picked up by a co-worker in Vermont (big kudos to Phil Joseph for picking up) and he still has yet to come down to drop them off.  I cannot complain, I only paid $100 for the set of four.  The tires on them are not adequate for the weight of the van, but until I get it ready for driving, they will do to move around, to and from the garage.  I will be trying that out later tomorrow, determining offset needs (and whether I need a spacer) and then I can order longer lug bolts to accommodate the alloy wheels thicker seat.

Picked up a spare tire carrier from a Nissan Pathfinder today.  Guy wanted $40 for it (with a Nissan spare) We ended up settling for $20 and a 12 pack of berry flavor Hydrive (caffeinated water, I get free) Fairly certain I can modify the bracketry enough to move the spare onto the back hatch.  Normally, for those who do not know, the spare is under the driver/passenger seats in a 'clamshell' under the car.  Now that a larger wheel and tire is on the way, this larger diameter will not fit in he clamshell without modification.

Also got her a new battery, ordered up a second battery kit from Go Westy to wire up a back up battery, and found a grab handle on ebay to install on the drivers side (to match the passenger side).  Do not know why they did not install at factory, but for 12 bucks delivered, I couldn't pass it up.

This week is supposed to warm up significantly, so I am happy I have stuff to play with when it does.

Last one for the day.

Been running around a bit today, and just had to replace a limit switch in my furnace.  20 degrees out, needed heat!

Anyway, got to tinkering with the van today. (I should really name her soon).  Wanted to replace the left taillight lens (found a pair on ebay for 30 bucks shipped), and ensure all the lights were working.  Tailights are easy on a Vanagon.  Four screws and they drop out.  Panel on back of lens carrier opens up and you have access to the bulbs.  One problem with the Vanagons is the lack of adequate taillight visability on the rear of the van.  The location plays a part in this, as well as the inadequate bulbs that came in the vans.  A quick trip to Napa yielded some higher output bulbs (the LED ones tend to run too hot and can melt the lens) and voila, tailights working, directionals working and a quick test on the brakes yeilds . . .nothing.  Given the aforementioned 20 degree weather, I shall opt not to crawl under dash to check brake switch today.



Side marker bulb fixture



Instead I look to the front end lighting.  The headlights were upgraded to a Hella H-4, but upon a quick viewing, I did not see the headlight relay upgrade necessary to support the full amount of juice the halogen bulbs will require.  Put that on the 'buy' list.

Then seeing that the drivers corner marker lamp is out, I pull off the lens to find a blob of oxidation and corrosion.  No wonder it is not working.  Yank it out, clean off the lens and put a couple bulb sockets on the 'buy' list.

The buy list is ever growing, and I am OK with that.  I would rather know exactly what has been done, and be sure its done right.  Probably why I have thus far refused to get rid of the older Suburban and Mercedes.  I know whats been done, I know every creak and sound, and where I stand.  With the van, I am now in unchartered teritory and need to get my bearings quick.

Flooring?

So having owned a Vanagon before, and having used said Vanagon for everything from beach visits to camping at base of Mount Washington so that we could be the first ones up Tuckerman Ravine, I am well aware of the beating a carpet in the back of the van is subjected.  Keeping this in mind, I considered my options for a floor covering that would be ideal to handle the traffic, be easy to clean, and be attractive enough to warrant the expenses associated with the installation.

I first thought about a Pergo style floor.  Thinking a floating laminate floor would be inexpensive, good looking have a decent wearability to handle a three year olds ambivalence to muddy boots.  I chose to avoid that option as any moisture may delaminate the flooring.  Although the costs to repair would be minimal, I tried to find something else.

I then thought of a linoleum over a 1/4 inch luan.  Then quickly thought the appearance would not satisfy my better half.

I was then presented with a few other ideas via the internet and thought I had chosen a suitable option when my neighbor, a general contractor, stopped by to see my new driveway ornament.  When I was giving the tour, I presented my thoughts on a decent flooring option, and he then offered an alternative.  He gifted a box of prefinished Carribbean Walnut hardwood flooring!  Perfect idea; inexpensive, good looking, wears well and the box contains enough to do the floor and have some left over for any potential repairs.  Its a bit heavier than I wanted, but we shall see how well it installs.

So what have I gotten myself into?

A 1984 Vanagon had its quirks when it was new, nevermind now that it is 25 plus years later.  They are vastly underpowered and have a significant amount of road noise ( I base this opinion on a comparison of my 94 Mercedes E420 and a 99 GMC Suburban, both well insulated vehicles).  Also having a number of years behind the wheel of one (or two).

On the plus side, its a completely mobile campsite with versatility and fairly well off ergonomically.  I am definately not the hippie type, and the pre-existing Dave Matthews Band and Grateful dead stickers that adorned the back glass were the first things to go.  Not that I have any animosity towards those who follow that lifestyle, its just not me.

This Vanagon had been used, and used well.  It was devoid of carpets, needed a real good cleaning and some TLC.  It had been previously painted and was in somewhat acceptable condition as far as appearance goes.  Having had some experience in the world of automotive body repair, I knew what to look for when it came to flaws.  There were no discernable mistakes in judgement when it came to the prep and execution of the previously mentioned paint job.  Nothing that made me think $500 special at the local MAACO.

It has some love bumps, had the rear bumper inside the van on the bed along with some other miscellany, and ran like it needed a tune-up ten years ago.  All in all, its was to be a work in progress.  Something to share with my family (read Son), and was to take a period of time to get it where I would be happy to take it anywhere.  This is much of what we have to deal with here in the Northeast.  Things rust.  Things break from the cold, harsh winters.  And stuff will need to be replaced.  That said, the family has embraced this idea to a degree that I could not have hoped for in my wildest dreams, and so the pressure is on to deliver in my promises of offering the world up the way I saw it back in the 70's and 80's.

So what is the plan?

It has been a month since I have brought this beauty home.  It was an ordeal getting it from Connecticut to Massachusetts.  Not a long way, but the weather was not that cooperative.  It had snowed a couple feet the day prior to me going to get it, so I postponed the pick up a couple days, and it snowed again.  This time I was determined, rented a trailer from the local UHaul (a location that I will never do business with again) and scheduled a pick up on a Friday after I got out of work. 

When I get there, the owner did not bother to shovel, and the roads around it are covered in a thin sheet of ice.  The latter would be the real problem, as slippery surfaces and poor tires are not conducive to getting a 5000 pound vehicle up on a trailer.  After an hour and a half of work, we had it on the trailer.  I forked over the cash, got my paperwork and started the 200 miles home.  The Suburban handled the weight like a champ, but it has always been my opinion having spent MANY miles on the roadways of New England (currently averaging 3500 miles a month) that Connecticut and New York drivers are the worst.  This coupled with weather conditions and restrictions on what roads a trailer can travel upon, made for a stressful ride. 

So since I have brought the van home, it has snowed more this year than I can remember.  I think in January we received 5 feet or so.  Just when you get it cleaned out, another storm blows through.  And although I have a two car garage, it is filled with Harleys, lawn tractors and catering equipment.  So there is no room currently for a tall VW Vanagon.  This snow has cramped my work schedule as I had planned to have a dozen things completed by now. I have spent more time performing snow removal and thinking about what I wanted to do, rather than actually completing my list.

I have been purchasing the items I need to get things completed.  Go Westy, Vanagon Cafe, Bus Depot have been a great resource for parts and information, and I have all the items ready to do the tune up.  Hoses, plugs, plug wires, cap, rotor, a new water pump, coolant for a flushing, and a new K&N air filter.  I have also started amassing a collection of items for a complete brake service, and have ordered the new front carpets.

Ok, now I have done it.

I bought myself another Vanagon.  Not that these things are huge events in the world or generally worthy of writing about, but having grown up seeing most of the East Coast (plus) from the windows of one or another VW camper, it is significant to me that I will now be able to share these same memories with my (now) 3 year old and from the same vantage point.

Already looking to do some camping.

Most of this posting stuff will be a history for myself, what I did and how I did it.  But if someone out there finds usefulness (or amusement) in my rantings, then so be it.

The vanagon I bought is a 1984.  First year of the water cooled engine, and one of the years that my family owned in the past.  They actually had 7 VW vans from 1970 through 1986.  I bought the 86 and sold it in 1995 when the vehicle was doing nothing but sitting while I played Wall Street.  Hated Wall Street and hated the fact that I sold my van even more.