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 Our new bus project

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Dave
2265cc
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Location : Odessa

PostSubject: Our new bus project   6/22/2011, 4:27 pm

I recently talked my wife into purchasing a bay
window as our first bus. We're no stranger to VW's but this is our
first type 2. We enjoy camping at VW shows, and we also have a rail
buggy we take to the woods a few times a year. Until now, we've tent
camped, but are growing tired of that. After hanging out in a friends
early bay westy, we decided a westy could work for us fine.

I honestly only looked for a week,
but as soon as this bus came up on the samba it seemed perfect for us.
My wife's favorite color is green, the bus seems in very good shape
minus the motor (more on that in a minute), and best of all, it seemed
like a very good deal. After a very long and nervous weekend of waiting
to get ahold of the seller, I drug my friend and my trailer from Pasco county to Sarasota (a little over 100 miles) to go and get it. We
paid the asking price of $1500 which I think is more than fair,
especially considering how the bays are jumping in popularity around around here.



The bus is a 78 Westy. It really doesn't have much rust. Around the
windshield (mainly the bottom), bottom of the nose at the floors (not
bad), the floors at the step in front of the front tire, and a couple of
very small spots on the cargo floor (the worst is from the leaking vent
window in the back on the drivers side, but it still isn't bad).



The interior is in very good shape, with only the cooler cabinet being
water damaged (from that leaky window). It was included so I can use it
as a template if we decide to do that. All of the latches are in place
and work.



The rock and roll bed and rear bed cushion look brand new, the front
seats are in good shape with some wear on the covers. The top cushion
on the roof looks brand new, but it's missing the extension pieces that
go in the opening. It's missing the childs cot, but came with all
curtains (even the wrap around for the windshield and front windows) as
well as the mosquito net for the rear hatch.



OK, so our plans are to preserve the interior and the body and drive the heck out of it.



Mechanically, I plan to swap a
Chevy Ecotec 2.2 for an engine. I have a motor, computer and harness in
my garage that I was saving for our next rail buggy. I intend to mount
a radiator between the frame rails.



I also plan to build a rear disk brake setup. I hate drum brakes, and
as I said, I intend to pull our rail buggy with it on a trailer, so I'd
love as much braking as possible.



Here are the pics from the ad. I'll take some better pics of the rust and document my progress.



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the-jerm
Crew Chief
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Location : Sorrysota physically, lost mentally

PostSubject: Re: Our new bus project   6/22/2011, 7:21 pm

Love the color. Congrats on a great deal! Definitely post your progress as you go.
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VWSPD
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Location : here

PostSubject: Re: Our new bus project   6/22/2011, 8:22 pm

nice find! looks like some good times ahead for you. can't wait to see the 2.2 set up.
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MadMike
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Location : Brandon

PostSubject: Re: Our new bus project   6/22/2011, 10:38 pm

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K1
Admin
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Location : in the back shed

PostSubject: Re: Our new bus project   6/23/2011, 1:28 am

Great find Dave Smile Keep us posted on the restore Smile

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Hellafast
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Location : Horizontally opposed.

PostSubject: Re: Our new bus project   6/23/2011, 8:57 am

Can't wait to see it.
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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   6/24/2011, 12:54 am

So after discussing with my wife we want to be able to drive it Bug Jam weekend. To facilitate that, I ordered the adapter kit today from Kennedy. They said 4 weeks, I know it's probably closer to 6. That's why I ordered it today because I have 3 weeks off in August from school so I'm hoping to be able to do most of the motor swap during that break.
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krakr14
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Location : Cape Coral FL

PostSubject: Re: Our new bus project   6/24/2011, 10:02 am

very nice bus
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herc1999
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Location : Seminole, Fl

PostSubject: Re: Our new bus project   6/24/2011, 6:00 pm

COOL!!
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Tomasz
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PostSubject: Re: Our new bus project   6/24/2011, 7:47 pm

You should come to Bulli Brigade / camp at Ft. DeSoto the night before since it's a camper.


Dave wrote:
So after discussing with my wife we want to be able to drive it Bug Jam weekend.
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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   6/24/2011, 8:11 pm

We were thinking of driving to Kips and camping there, then driving up to Bulli the next morning. But yeah, that's why we want it drivable for Bug Jam.
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Tomasz
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PostSubject: Re: Our new bus project   6/24/2011, 8:13 pm

well, we have common goals then, that is to somehow make our buses driveable that weekend Smile

I've camped at Kips for the past 5 years, but now that Bulli is at Ft. DeSoto there is no way I'm spending the night there

Dave wrote:
We were thinking of driving to Kips and camping there, then driving up to Bulli the next morning. But yeah, that's why we want it drivable for Bug Jam.
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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   6/24/2011, 8:15 pm

I thought about camping at Ft. Desoto, but I figured the good spots are taken, and that's going to be a drive from Kips, so I'd rather crash at Kips and wake up at a decent time Saturday to head to Bulli.
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Tomasz
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PostSubject: Re: Our new bus project   6/24/2011, 8:18 pm

make sure you have earlplugs with you as it doesn't really get quiet or dark 'till about 3-4am followed by people start leaving/reving up their engines at 6am Wink

hell of a party though

Dave wrote:
I thought about camping at Ft. Desoto, but I figured the good spots are taken, and that's going to be a drive from Kips, so I'd rather crash at Kips and wake up at a decent time Saturday to head to Bulli.


Last edited by Tomasz on 6/24/2011, 8:20 pm; edited 1 time in total
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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   6/24/2011, 8:20 pm

haha thanks for the warning.
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K1
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Location : in the back shed

PostSubject: Re: Our new bus project   6/24/2011, 9:28 pm

Dave, I moved the Thread to the Wrenching Section Smile Seems like you will have a lot of that going on Smile

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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   7/20/2011, 3:29 pm

Just got my adapter kit from Kennedy. This one actually came earlier than they said. I'm hoping to get the T4 motor out soon so I can hit the ground running once school gets out.

Oh, I also ordered a battery tray for the right side. The stock one is very rusty, and I figure the best time to replace it is with the motor out.
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Dave
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Location : Odessa

PostSubject: Re: Our new bus project   8/4/2011, 11:42 pm

OK so I made some progress today.

After measuring and thinking about it, I realized I needed to cut the back "apron" out. The motor fits with it, but not with the studs, flywheel, pressure plate etc, hanging off the back. I couldn't get it up and into the trans as one piece. So I cut a section of the apron out and will weld up tabs to bolt it back in so all you'll see is 2 lines. I cut it off center because I wanted to leave the part of the engine bay with the VIN plate intact so it wouldn't appear suspicious. The bumper should hide most of this.

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Next up I was able to slide the motor in to see how bad my interference would be with the back of the motor (the fuel tank was removed so I could slide the motor all the way back without that hitting). As I expected, I had interference with the metal coolant line that runs across the back of the head. It was hitting on the front edge of the shelf that the gas tank sits on (where the foam seal goes for the T4). So I cut that out, being careful not to cut into the top trans mounts (yet not careful enough to avoid cutting the CRAP out of my hand when the abrasive blade caught and blew up). This is what I cut away. I'm going to cut more on the right side (looking in the back) because the rubber radiator hose still hits.
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So with that out of the way, the motor slides all the way in, but the EGR provision on the back of the head will hit the gas tank. Not as bad as I thought though. So I started looking at the motor, and realized that I can block the EGR port on the exhaust side with some putty allowing me to cut the big protrusion off the back of the head, eliminating that from hitting. I still may have some interference on the back of the head where the power steering pump bolts up (it's driven off the back of the cam) but I should be able to massage that with a hammer to avoid cutting the tank. (you can see the EGR mount in the middle of the head, and the power steering drive right behind the oil cap).
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So this is what the motor looks like sitting in the engine bay. It's a bit tight at the top, but I should be fine. I'm happy to see I'll have good room for the exhaust and air filter setups. I'm sad to see I'll have to come up with something for the throttle cable Sad
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I'm going to take the next 4 days off from the bus. I know I just got started, but my wife has the next 4 days off and we don't get to see each other very much (I'm a full time nursing student, she works 7 days a week to put me through school). I don't have to go back to school until August 22nd though so I'm going to make a big push the next couple of weeks.
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