Well, Ferdinand has come a long way since June and he's working well. I've managed to take him from being a shell in a field, to a fully running and (mostly) functioning Westy, albeit slow Westy.
The 1.6l diesel engine is a great little motor and I'm all about diesel, but VW didn't factor in the importance of "time" when they made this motor. I enjoy driving it, and getting 30mpg, but it sure takes a great deal of time to get anywhere. Just a few weeks ago, I had my son time us from a traffic meter on an onramp to see how long it would take to get up to 60mph. 1 minute, 20 seconds! Amazingly slow.
Our intentions for this van from day 1, was to get him all working, driving and then slowly move towards a motor upgrade. I've been researching since June on what will work/not work, the costs, the "time", longevity, ease of work involved, etc.
A few weeks ago, came to the conclusion that the best route for us at this point in time, is to do a Subaru 2.5 swap into Ferdinand. Then, as it happens, we did some car swapping and ended up being able to afford to take on the conversion project a little sooner that I'd anticipated. So, I've nailed down all the details on the motor, the conversion, the transaxle and the when, why and how it will all come together.
The Motor:
I'm going with a 2.5 naturally aspirated SOHC motor from 2000-2004 and having it fully rebuilt here locally with new pistons, polished crank, etc... a full rebuild kit.
The Parts:
After talking in great detail with many people who have done this conversion, and endless emails and Facebook posts with manufacturers of various products, I've concluded that though all of the conversion kits/parts have their pros/cons, that I'm sold on the Rocky Mountain Westy package. I really like to attention to detail on the parts and their service has been amazing. I'm also very fond of the fact that their focus is mostly geared towards creating awesome products for the VW Vanagon. Mike, Mark and Joe have been very helpful and easy to work with. My parts kit will be ordered up within a few weeks and they should have my wiring harness in their hands around the same time.
The Transaxle:
I was originally going to pick up a gasser transaxle (diesel trans won't work easily with Subie) and get it rebuilt and re-geared before installation. After much discussion about gear ratios, ring and pinion, tire sizes, RPM's, etc, I think I'm going to go ahead and install the stock gasser trans with the Subie, drive it a bit, settle in on a tire size and then re-gear accordingly. Yes, I'll have to pull the trans again, but I think this is a better approach. The 2.5 is definitely going to need a higher 4th and probably 3rd, but I may swap some tires around and don't want to commit to a certain ratio just yet.
Timeframe:
I have to leave for a work trip and won't be back until around Christmas, so my plan is to get everything lined up and begin the "production" right after Christmas and into January. I hope to get it all dialed in before Spring rolls around so that we (my wife, kids) can get in some good road trips this summer.
Obstacles:
Being that I have diesel, there are a few things that need to get addressed.
1. The lack of a fuel pump... going to have to add one.
2. I need larger coolant lines as the diesel uses 1.5" lines and I'll probably swap out the radiator at that time.
3. Battery is in the engine compartment and I might try and leave it there if it doesn't hinder the motor.
4. Need to install a charcoal canister and vent the fuel lines into it. Diesel tanks just vent under the body.
Little piddly stuff that just needs to get addressed, but all in all, it should go well. I have 3 good friends, all with Subie 2.2 conversions who know the trials and tribulations of conversions, so I think I'm in good hands.
Definitely looking forward to having some power. The stock diesel puts out about 55hp and the upgrade to 2.5 triples that, which means I'll also want to address the brakes and make sure I can stop all that mass.
I know that I'll probably get booted from the Vanagon-Diesel group once they read this, but a TDI build just isn't in the cards for us right now, especially since all my Van friends that are helping, drive Subie powered rigs.
Keep your eyes peeled for the process in a month or so and feel free to add comments below.
My love for these quirky pieces of German machinery has led me on a voyage of learning, heartbreak, passion and travel. They are wonderful creatures that are commonly misunderstood. I plan to share as much as I can along this journey in hope of helping others enjoy theirs as well.
Vanagon Redwoods
Thursday, November 10, 2016
Friday, October 21, 2016
Cabinet Mods
When I had my Westy Weekender, I loved the full width rear seat. You could prop a pillow up and sit sideways at the table... It was cozy and comfy. Now, I love my full camper, but the extra cabinets do hinder the comfort factor slightly, unless you're willing to operate a saw and get all mad scientist on it the way I did.
I had seen a few vans where they chopped the cabinet down (the one aft of the cooking cabinet and next to the seat) in order to add more chillaxin lounge space, and I liked it. So, I pulled that cabinet out, took some measurements and went to town.
I had planned on decreasing the water tank size anyhow, so removing it wasn't a problem for me. I'll be adding a 4-5 gallon fresh water tank under the sink pretty soon.
Originally I was going to just chop it down and re-use the top, but the way it's made, doesn't allow for east deconstruction and re-contruction, so I just picked up some 3/8" Birch and made a whole new top, keeping just one access port/cubby on the backside. The lower access on the front side, is plenty for what I need to store.
In the back cubby, I cut out some birch and lined the inside nicely. I may end up raising the floor in that cubby and creating a hidden compartment for valuables at some point.
When re-upholster the seats/cushions, I'm going to have a small pad made for new bench area that matches and then keep a few pillows in there that will double as our sleeping pillows.
I also made sure to buy enough birch to lay down a new floor and did that at the same time.
I had seen a few vans where they chopped the cabinet down (the one aft of the cooking cabinet and next to the seat) in order to add more chillaxin lounge space, and I liked it. So, I pulled that cabinet out, took some measurements and went to town.
I had planned on decreasing the water tank size anyhow, so removing it wasn't a problem for me. I'll be adding a 4-5 gallon fresh water tank under the sink pretty soon.
Originally I was going to just chop it down and re-use the top, but the way it's made, doesn't allow for east deconstruction and re-contruction, so I just picked up some 3/8" Birch and made a whole new top, keeping just one access port/cubby on the backside. The lower access on the front side, is plenty for what I need to store.
In the back cubby, I cut out some birch and lined the inside nicely. I may end up raising the floor in that cubby and creating a hidden compartment for valuables at some point.
When re-upholster the seats/cushions, I'm going to have a small pad made for new bench area that matches and then keep a few pillows in there that will double as our sleeping pillows.
I also made sure to buy enough birch to lay down a new floor and did that at the same time.
Future cabinet plans include converting the rear cabinet to be about 4-5" thinner in an attempt to have more shoulder room. I'll be staining and sealing the wood (floor too) as well to protect from spills/stains.
Thursday, October 13, 2016
Braking Me Bad
Ever since I picked up Ferdinand a few months back, his brakes have been an issue. I first tackled the rear drums because I had a leaking wheel cylinder and I purchased all new parts (wheel cylinders, shoes and hardware/springs). It helped a little, but there was more going on beside just worn rear components. The drums were smooth, so I didn't have them machined.
The front pads looked near new and there were no leaks, so I skipped over those and dove into the dash to take a look around at the hydraulic system.
If you are new to Vanagons, you'll soon realized that the master cylinder, brake booster and fill reservoir are underneath the instrument console. You simply pop off the console to fill your brake fluid. It's kinda weird pouring fluid into your dash between the speedo and the clock, but it works.
Upon inspection of the booster and MC (master cylinder), I noticed a fair amount of rust underneath the MC and what appeared to be brake fluid leaking slowly from the booster so, I began researching parts, namely the brake booster itself.
My braking symptoms seemed more booster related because the brakes would work great on the first press of the pedal, and then they would be full manual (no power) on the 2 press of the pedal, so I assumed at this point that the booster was bad or that I had a vacuum line leaking air somewhere.
I checked my check valve in the engine compartment and it seemed fine as well as the line leading all the way forward to the booster. So, I picked up a "newer" booster from my Vanagon parts friend and began tearing apart the dash.
You can upgrade your stock booster to that from a BMW (E30 booster), but it requires a little adaptation that I didn't want to mess with right now. That and having a bigger booster on a 35 year old braking system seemed like trouble waiting to happen. I might eventually go that route, but I'll want to upgrade other components before I do so.
The stock booster is big and hard to remove. You have to pretty much disassemble the drivers side of the dash to get at it. After removing the steering wheel, steering column, upper console, master cylinder and the 2 dash supports, I was able to squeak it out of there. It's a pain and I don't recommend it for the non-mechanical person. In the process, I also pulled the clutch master and checked it over for leaks as well, tried to clean up the seals in the process.
After getting the booster out, I did everything in reverse putting in the newer one, starting with the pedal assembly and clutch master, then the booster, followed by the MC, all of it's lines plugs and dash supports. I then re-assembed the steering column and steering wheel.
I then had to re-bleed the system because I had taken the clutch master off the pedal assembly to get the booster free. In retrospect, I shouldn't have done that because it added a great deal of extra time because of the bleed job, but it seemed like the only way to get the pedal assembly and booster out of the dash.
The clutch bleeding didn't go well and I ended up hitting up Harbor Freight to get a pressure bleeder which helped a great deal. Best $30 I've ever spent. The problem was because I didn't bench bleed the clutch master before re-installing, but the pressure bleeder took care of that.
All said and done, the brakes were "better", but still fading on the boost after the first press of the pedal. I was bummed. I went back online and did some research and decided that the MC was bad and ended up ordering a new one from Van Cafe (because I can get stuff overnight from them PLUS a chocolate chip cookie!) and planned to swap out the MC the next day.
Today, I dove into it, bench bled the MC and installed it without a hitch. I then bled the entire system and voila! brakes are feeling awesome. I'm pretty sure the MC was the culprit all along, but my booster was looking pretty bad as well and it was probably just a matter of time before it gave up the good fight.
The best part of the day, happened while I was under the engine bleeding my rear brakes and decided to investigate my ongoing oil leak a little further. upon inspection, I found that the oil was leaking from a bolt hole in the block that was somehow missing its bolt. Not sure why or where, but I found a bolt, filled the hole and my oil leak is gone. bam! Happy camper... literally.
Took him out into traffic (something I've been afraid to do until now) this evening and hit up Trader Joes, but not without admiring him the evening sun.
Monday, October 3, 2016
Headlight Superbright! LED upgrade
Lights... we need them and the brighter the better. I've always been in search of brighter lighting options by adding driving lights, fog lights, LED's etc., in an attempt to see better and make older vehicles a bit more modern.
Easy installation and it only took about 10 minutes start to finish.
Here are the comparison pics in my driveway.
My '82 Diesel had original 7" lights with stock grill and I wanted to upgrade the lights without changing the look of the front end. Many folks opt for the SA grill swap these days, but for some reason, I'm partial to the original stock grill.
In search of brighter headlamp options, I ran across VintageCarLED's and was sold on the idea of going with LED's on "Ferdinand" the van. On previous vans, I ran the H4's and was happy with the output, but they had a pretty large voltage draw and would get pretty hot when sitting for too long.
So, after exchanging a few messages back and forth with Thomas at VintagecarLED, I ordered up a pair of VC3500 Classic's that are rated at 3500 Lumens.
Once they arrived, I was impressed right off with the quality of the product right out of the box.
Easy installation and it only took about 10 minutes start to finish.
Here are the comparison pics in my driveway.
My iPhone camera doesn't do it justice, but the lights are amazingly bright and crisp. |
Before and after of the lights in the grill. Huge difference!
VC3500 Specs from their website:
Wattage: 25W
Voltage: DC 12V – 24V
Flux: 3500Lm
Lifespan: 30,000 Run Hours
Color: 6500Kelvin (Pure White)
Operating Temperature: -40F to 180F
VC3500 Specs from their website:
Wattage: 25W
Voltage: DC 12V – 24V
Flux: 3500Lm
Lifespan: 30,000 Run Hours
Color: 6500Kelvin (Pure White)
Operating Temperature: -40F to 180F
Great simple upgrade and I highly recommend these lights or any other models that they offer.
Monday, September 5, 2016
Stock Bumper Facelift
I will eventually replace my front bumper with something a bike more substantial. The one that came with the van was slightly bent, the rub strip was missing and the chrome was looking a bit tarnished.
So, I decided to throw a little black satin paint on it and call it good.
So, I decided to throw a little black satin paint on it and call it good.
However, I decided that I wanted to make it different. My original thought was to put stainless carriage bolts across the front to give it somewhat of a riveted industrial look, but there's not a great deal of space behind it for a nut. So I removed all the bolts that hold the rub strip on and bought small black plastic plugs to fill the holes.
After that, I added some grip tape strips to the top so I don't slip off when climbing up to check the cargo space.
Simple quick hack.
Sunday, September 4, 2016
Skylight Rebuild
My poptop came from a newer van, so luckily, I get a skylight. Most of the early model pop tops didn't have a skylight. Well, mine came with a hole and an actual skylight lens, but no hardware or seal.
I put it off for a while because the weather was awesome and I wasn't concerned so much. About 2 weeks ago, I knew that I was going to be heading back to work for about 5-6 weeks and didn't want to leave the van with a hole in his top. So, I bit the bullet and ordered up all the necessary pieces from GoWesty to install the skylight.
You can purchase the entire skylight kit from various manufacturers for about $150ish+, but since I already had the lens, I had to piecemeal it together and order all the small parts individually.
GoWesty kit or BusDepot kit
After it all arrived, I laid it all out, cleaned up the hole in the pop top the best I could, opened up Youtube to the GoWesty channel and followed the simple instructions. All said and done, it took me about 25 minutes and it turned out perfect.
I put it off for a while because the weather was awesome and I wasn't concerned so much. About 2 weeks ago, I knew that I was going to be heading back to work for about 5-6 weeks and didn't want to leave the van with a hole in his top. So, I bit the bullet and ordered up all the necessary pieces from GoWesty to install the skylight.
You can purchase the entire skylight kit from various manufacturers for about $150ish+, but since I already had the lens, I had to piecemeal it together and order all the small parts individually.
GoWesty kit or BusDepot kit
After it all arrived, I laid it all out, cleaned up the hole in the pop top the best I could, opened up Youtube to the GoWesty channel and followed the simple instructions. All said and done, it took me about 25 minutes and it turned out perfect.
Wheel Upgrade
14" wheels are too small but they work. Most everyone who owns a Westy long enough will upgrade to a 15" or even a 16". My van came with 14" steel wheels, complete with rotten tires that I wouldn't trust on a trip around the block. However, tucked away in the back of the van, was a set of 4 15" Ronal R9's with damn-near brand new tires. I just needed to get some longer lug bolts/nuts and clean them up a bit.
Ronal has been making wheels for a long time and I didn't know too much about them aside from seeing the name now and then. I guess they were pretty popular in Europe at least from what I can gather. I did a little research and finally figured out mine were R9's. They had been painted and re-painted quite a few times, so I had my work cut out for me.
My typical approach when painting wheels is this:
-Pressure wash
-Degrease
-Sand lightly
-1 coat of self etching primer
-sand
-2 coats of wheel paint (In this case, a satin black on the outer part of wheel and a texturized paint on the spokes since these already had a texture on them). I use a brand of paint from Autozone, it runs about $8/can.
It took me about 6 hours worth of work, but they turned out pretty good and gave the van a whole new presence.
Ronal has been making wheels for a long time and I didn't know too much about them aside from seeing the name now and then. I guess they were pretty popular in Europe at least from what I can gather. I did a little research and finally figured out mine were R9's. They had been painted and re-painted quite a few times, so I had my work cut out for me.
My typical approach when painting wheels is this:
-Pressure wash
-Degrease
-Sand lightly
-1 coat of self etching primer
-sand
-2 coats of wheel paint (In this case, a satin black on the outer part of wheel and a texturized paint on the spokes since these already had a texture on them). I use a brand of paint from Autozone, it runs about $8/can.
It took me about 6 hours worth of work, but they turned out pretty good and gave the van a whole new presence.
Interior Panel Rejunevation
Ferdinand is 34 years old and his interior panels are original. When I bought him, he'd been sitting in a field for 2 years and was missing some windows. Needless to say, moisture had gotten in and warped some of the panels. The paper coatings were bubbling and looking bad, but I didn't really care at the time because I knew that I was going to rip them all out at some point and replace them with an upgraded material.
However, once I got him home and started to strip him down to bare bones, I found that most of the panels were still in pretty good shape aside from the paper coatings (I call it wallpaper) coming off. I left this project off the initial priority list because I didn't care about the aesthetics so much as getting him running and trustworthy.
Well, a few weeks back I was satisfied with the progress and decided to develop a plan for making the interior looking better. I spent an hour or two peeling and cutting away old paper off the panels before deciding to pull out the heat gun. Once I fired that up, things really started to take action. Using a razor blade and a small putty knife, I was able to get all of the old coating off the interior to expose the raw panel in all its glory.
The material had an interesting texture and appearance that reminded me of bamboo or tweed, or a mixture of the two. At any rate, I kinda like it and for now, I'm leaving it. When I'm ready, I'm going to be pulling each panel and applying some sort of paint, but I need to decide on a texture, color... or potentially I may decide to try and apply some fabric using a high-heat spray adhesive.
I really like some of the aftermarket interior kits you can buy, but I get more satisfaction out of crafting something on my own, not to mention the cost savings.
However, once I got him home and started to strip him down to bare bones, I found that most of the panels were still in pretty good shape aside from the paper coatings (I call it wallpaper) coming off. I left this project off the initial priority list because I didn't care about the aesthetics so much as getting him running and trustworthy.
Well, a few weeks back I was satisfied with the progress and decided to develop a plan for making the interior looking better. I spent an hour or two peeling and cutting away old paper off the panels before deciding to pull out the heat gun. Once I fired that up, things really started to take action. Using a razor blade and a small putty knife, I was able to get all of the old coating off the interior to expose the raw panel in all its glory.
The material had an interesting texture and appearance that reminded me of bamboo or tweed, or a mixture of the two. At any rate, I kinda like it and for now, I'm leaving it. When I'm ready, I'm going to be pulling each panel and applying some sort of paint, but I need to decide on a texture, color... or potentially I may decide to try and apply some fabric using a high-heat spray adhesive.
I really like some of the aftermarket interior kits you can buy, but I get more satisfaction out of crafting something on my own, not to mention the cost savings.
Thursday, September 1, 2016
Vanagon Geekness: Repair Resources
It's a Vanagon, so unfortunately, at some point in your "relationship", you will find yourself sitting alongside the road trying to figure out why your van won't go.
There are numerous threads about "what to bring" and keep stocked in your van on road trips, but here's a quick hack that I like as well.
Mobile e-Manual: Many of us have been in the age of technology long enough to have an old device laying around that isn't being used. An old smartphone, an outdated tablet, maybe a laptop? I went online and with a little digging, managed to find a PDF copy of the Bentley repair manual. I then transferred that PDF to an old Motorola tablet and it gets kept in the van. It's also handy for just tinkering around in the driveway, rather than getting greasy fingers on those beautiful white paper pages of the original manual.
If this device has internet access, make a list of favorites or links to manufacturers, repair facilities, Facebook groups like "Vanagon Help" or "Vanagon Owners" so that you have the resources to help you get your baby back rolling.
I also like that you can zoom in on illustrations since my eyesight isn't what it was a few years ago.
Anyhow, just an idea...
Wednesday, August 31, 2016
Upper Control Arm fix
I've had a few Vanagons now and I'm quite privy to upper control arm bushing failure. It's an obvious sound and feeling when these little $20 parts go bad and they pretty easy to fix, so I wasn't alarmed when I heard and felt mine rattling around down there on the passenger side.
Because they can really throw off your alignment, it's good to nip them in the bud and swap them out. I ordered up the parts from VanCafe because I was craving big cookie and I needed the parts the next day (they are only a few hours away), and decided to knock it out the next morning.
As soon as I got the van jacked up and had the wheel off the ground, I realized that I had a bit more going on down there. The bushings were snug, but the oval sleeve used mount that the upper control arm bolts to, was separated from the frame mount. Not something I had expected, or seen before.
So, I took a few pics with my phone up in the wheel-well to get a better look (because you can't see the back side of the shock tower) and was baffled as to how I was going to remedy the situation. The area up inside the wheel well is too narrow to get in there with a mig welder and being able to get a good solid weld on there would not be possible even if you could.
So, I called a good friend, also a Vanagon geek like myself, who has a ton more experience with bigger jobs like this, not to mention he's an amazing welder and mechanic. I shared some pics and he decided to come over and take a look.
As soon as he arrived, we agreed the best course of action would be to get it to his house and cut open the floor under the passenger seat so that we can create an access to the shock tower and upper control arm mount.
So, we removed the seat, drilled some holes and carefully cut a 12"x12" opening under the seat with a sawsall.
We were lucky that the mount/sleeve broke off pretty cleanly and we could see exactly where it was supposed to go. We then cleaned up the metal and welded the part back in, but not before adding an extra piece of metal to reinforce the sleeve in the inboard side.
After that, a quick re-install of the control arm and we were done. We eyeballed the alignment and pretty much nailed it, but I'll be getting it aligned pretty soon when I install new suspension components.
All said and done, it was about 6 hours of work, 2 sub sandwiches and the existing bushings didn't even need to be replaced.
We welded the access port back in and cleaned it up with some good Rustoleum pain and you could hardly even tell we were there.
Tuesday, August 30, 2016
Rocker Panel Protection
When I purchased my first Vanagon, I was looking for ways to dress it up and personalize it a bit. I had a short list of things I could do to make it look "better than stock" without spending tons of money.
One of the first things that I did, was to add a bedliner product to the lower rocker panels of the van. I like the look of it because it breaks up the huge body panels a little and makes the van appear a bit taller than it is. I've always liked my vans to look a little more "rugged" and this is a quick way to accomplish this. It also adds a fair amount of protection to the lower section of the body to protect from rock ships, scrapes and eventually rust.
I did some research and asked around about various products and then decided to try out Rustoleum's Bedliner that is available in a spray can. I figured that for the price, I can go wrong and I could always touch it up should it chip, flake, crack, etc. This is available at most hardware stores, I purchased mine at the local Ace Hardware for about $9/can. The lower rocker panels on my van took about 3 cans total (one per side, then less than one for the front and rear sections).
Now, for any project that involved paint, you have to know that prep time is usually about 3-4x longer than actual application time. The masking, paint prep and "figuring it out" is always the longest part of the project.
Parts list:
2 Rolls of thin (1") Blue masking tape
1 Roll of the thicker (3") Blue masking tape
1 Roll of masking paper (about 10" wide)
1000 grit sandpaper
Paint Thinner
Clean rag
Piece of cardboard (to use as a shield)
Old towel or cardboard (or something to throw over wheels to avoid overspray)
The first part if figuring out your masking line. Do you want it go over the wheel wells or stay below and follow the body line. Do you want to do the area inside the door and step? do you want to continue it on the front and rear of the van and if so, where? All things you'll want to consider. The easiest option is to go online and Google "Vanagon rocker panel undercoating" or something along those lines and start seeing how other people tackled theirs. You can always add more later, but you don't want to go overboard and then think that less would've been better. Think it through.
Next, mask off your area with the thin tape and make sure your paintable edge is clean and that the tape is pressed down tight, otherwise you'll get paint under the tape and it'll look bad.
Then, once your happy with the line, use the thicker tape and masking paper to mask off the area/s that could potentially get overspray on them. This product doesn't put off too much mist, but it will end up finding its way onto the rest of the van. I usually mask up about 12" or so above the line and just be careful when I paint. I use the cardboard as a shield for anything else and I keep a rag hand with some paint thinner on it to remove any accidental overspray.
I've used this product on 3 different vehicles now and I love it. It's strong, looks good, goes on easy and it's affordable.
I unfortunately lost a few photos from this project, but I'll try to dig up what I can and add them into the post.
One of the first things that I did, was to add a bedliner product to the lower rocker panels of the van. I like the look of it because it breaks up the huge body panels a little and makes the van appear a bit taller than it is. I've always liked my vans to look a little more "rugged" and this is a quick way to accomplish this. It also adds a fair amount of protection to the lower section of the body to protect from rock ships, scrapes and eventually rust.
I did some research and asked around about various products and then decided to try out Rustoleum's Bedliner that is available in a spray can. I figured that for the price, I can go wrong and I could always touch it up should it chip, flake, crack, etc. This is available at most hardware stores, I purchased mine at the local Ace Hardware for about $9/can. The lower rocker panels on my van took about 3 cans total (one per side, then less than one for the front and rear sections).
Now, for any project that involved paint, you have to know that prep time is usually about 3-4x longer than actual application time. The masking, paint prep and "figuring it out" is always the longest part of the project.
Parts list:
2 Rolls of thin (1") Blue masking tape
1 Roll of the thicker (3") Blue masking tape
1 Roll of masking paper (about 10" wide)
1000 grit sandpaper
Paint Thinner
Clean rag
Piece of cardboard (to use as a shield)
Old towel or cardboard (or something to throw over wheels to avoid overspray)
my '86 Westy with undercoating |
The first part if figuring out your masking line. Do you want it go over the wheel wells or stay below and follow the body line. Do you want to do the area inside the door and step? do you want to continue it on the front and rear of the van and if so, where? All things you'll want to consider. The easiest option is to go online and Google "Vanagon rocker panel undercoating" or something along those lines and start seeing how other people tackled theirs. You can always add more later, but you don't want to go overboard and then think that less would've been better. Think it through.
Next, mask off your area with the thin tape and make sure your paintable edge is clean and that the tape is pressed down tight, otherwise you'll get paint under the tape and it'll look bad.
Then, once your happy with the line, use the thicker tape and masking paper to mask off the area/s that could potentially get overspray on them. This product doesn't put off too much mist, but it will end up finding its way onto the rest of the van. I usually mask up about 12" or so above the line and just be careful when I paint. I use the cardboard as a shield for anything else and I keep a rag hand with some paint thinner on it to remove any accidental overspray.
I've used this product on 3 different vehicles now and I love it. It's strong, looks good, goes on easy and it's affordable.
My '82 before |
My '82 after |
I unfortunately lost a few photos from this project, but I'll try to dig up what I can and add them into the post.
Monday, August 29, 2016
Sound and Temperature Insulation
When I picked up "Ferdinand" the '82 Diesel, I wanted to strip it down and check everything out before committing to the project. I did an inspection of the undercarriage/drivetrain and managed to get the motor running pretty good after sitting for a few years. I then began to tear apart the interior to inspect the panels for rust and corrosion. My end goal is to modify the existing cabinets slightly to be a bit more comfortable when camping. At any rate, to my surprise, there wasn't much cancer taking place aside from the driver's side seam behind the door. I wire-wheeled it down to bare metal, applied some Ospho and some rust control paint to stop the process and I think that'll hold her. The yellow stuff on the panel in the photo is the glue that is used at the factory to hold the fiberglass insulation in place.
Anyhow, since I had most of the panels out, I decided to take the time and replace the old fiberglass insulation with something new and add some sound dampening as well. I did a little research and decided to use a knock-off dampening material similar to Dynamat or Fatmat. Luckily, a good friend of mine had a bunch left over from doing his van and it cost me $0. It's a peel and stick application and it helps keep the panels from vibrating and gives the panels a bit more thickness to help keep the resonance down. I put pieces where my hands could fit: doors, firewall, side panels, etc. I put more detail into the footwell area with both the dampening and insulation to keep our feet a bit cooler when driving on hot days as well as wind noise. I also added some of the dampening material behind the front grill on the exterior and then sprayed over it with a rubberized undercoating to keep down wind and road noise.
Then using some peel and stick foil type insulation from Home Depot,
Anyhow, since I had most of the panels out, I decided to take the time and replace the old fiberglass insulation with something new and add some sound dampening as well. I did a little research and decided to use a knock-off dampening material similar to Dynamat or Fatmat. Luckily, a good friend of mine had a bunch left over from doing his van and it cost me $0. It's a peel and stick application and it helps keep the panels from vibrating and gives the panels a bit more thickness to help keep the resonance down. I put pieces where my hands could fit: doors, firewall, side panels, etc. I put more detail into the footwell area with both the dampening and insulation to keep our feet a bit cooler when driving on hot days as well as wind noise. I also added some of the dampening material behind the front grill on the exterior and then sprayed over it with a rubberized undercoating to keep down wind and road noise.
Then using some peel and stick foil type insulation from Home Depot,
I spread that over the same panels, getting it wherever I could. The end result so far has been great. I'm still formulating my plan for re-furbing the panels themselves, but I'll tackle that in a new post. I also am going to add a thin layer of insulation under the cargo area when I put in my new floor. I still have the headliner over the driver and passenger seat to tend to, but I'll re-insulate that when I pull the panel for refurb.
I notice a big difference in the way the van sounds and feels on the inside. When It been sitting in the sun for a while, I don't feel like I'm sitting in a steel box. Furthermore, the sound dampening material really make the doors sound solid upon closure. Pretty easy, cheap and satisfying project. If you haven't taken the time to pull your interior panels and inspect your "shell", I highly recommend doing so... You never know what might be lurking in there.
I notice a big difference in the way the van sounds and feels on the inside. When It been sitting in the sun for a while, I don't feel like I'm sitting in a steel box. Furthermore, the sound dampening material really make the doors sound solid upon closure. Pretty easy, cheap and satisfying project. If you haven't taken the time to pull your interior panels and inspect your "shell", I highly recommend doing so... You never know what might be lurking in there.
Welcome to Vanagon Geek!
Welcome to the new Vanagon Geek blog, where I will do my best to post pertinent info, product reviews, links, repairs, and pics about Vanagons and their nuances. I don't claim to be an expert on these wonderful creatures, but I've owned a few (3 Vanagons and Split-window) and am learning more each day. Together with my mechanic/nephew Trent (and his Subaru powered Bay window project), we'll be tackling various Vanagon topics and I'll post some trials and tribulations along the way.
My passion for these quirky vehicles began when I was just a few days old... so I'm told. An early model bay-window bus (1969) was the first vehicle I ever rode in as my parents brought me home from the hospital after entering the world. We camped and traveled around in this bus for quite a few years growing up, most of which I don't remember. As I grew, my father got involved with customizing vans, mostly Ford and Dodge, but it gave me some insight into how the interior of a box on wheels can be turned into a home and rolling sanctuary. It intrigued me and I began to really appreciate the potential of a "van".
In 2012, I began to re-obsess over the VW line of cars, in particular the Vanagon. I wanted one, and I wanted one bad. I sold my incredibly reliable Honda Element and purchased "Blanca", a 1986 Weekender Westy from a dealer in the Bay Area. She was beautiful and nearly completely rebuilt and clean. She cost me a pretty penny, and I took her a bit further by adding trick little add-ons, upgrades and niceties. Not long after that, I experienced a financial hardship as I was forced to close my business that I'd operated for 8 years. At this point, I had no "plan B" for a while, so I simply just lived the Vanagon lifestyle and we traveled and used it frequently. My wife and I discussed many career options, and I eventually decided on a career as a professional mariner and I needed to sell my van to pay for schooling. It was heartbreak, but the short-term loss would lead to a long-term gain.
So, off I went to a 2-year school out of town and landed a Coast Guard license which would allow me to drive tugboats on the West Coast (see my other blog on that career change). http://backtoseawithme.blogspot.com
Anyhow, I have now completed the needed schooling to be a licensed Mariner and am picking up where I left off with regards to my passion for Vanagons and VW's in general.
During the 2 years in school, I purchased a 1984 Westy with the intention of keeping it and fixing it up, but then flipped it for some more school money.
About 3 months ago, I did some trading and picked up "Ferdinand", a 1982 Diesel Westfalia that needed a ton of work, but had great potential. He is my current project and he will most likely be the focus of my blog, but I'll be working on some other Vanagons over time and will highlight those repairs and modifications as well.
Many years later, I joined the Navy and at some point, began to obsess over VW busses. I saved my money and one month after I was honorable discharged, I purchase my first bus, a 1967 21-window, nearly all original and beautiful. I loved that bus and drove it everywhere as my daily driver and even to this day, still get a little emotional over it. A few years later, I made the silly decision to sell it off (for profit of course) to get something that would get me up into the hills quickly for hiking, biking and recreation. I purchased a Landcruiser and started down of a path of obsession over those creatures as well, however I never lost my lust for the bus.
In 2012, I began to re-obsess over the VW line of cars, in particular the Vanagon. I wanted one, and I wanted one bad. I sold my incredibly reliable Honda Element and purchased "Blanca", a 1986 Weekender Westy from a dealer in the Bay Area. She was beautiful and nearly completely rebuilt and clean. She cost me a pretty penny, and I took her a bit further by adding trick little add-ons, upgrades and niceties. Not long after that, I experienced a financial hardship as I was forced to close my business that I'd operated for 8 years. At this point, I had no "plan B" for a while, so I simply just lived the Vanagon lifestyle and we traveled and used it frequently. My wife and I discussed many career options, and I eventually decided on a career as a professional mariner and I needed to sell my van to pay for schooling. It was heartbreak, but the short-term loss would lead to a long-term gain.
So, off I went to a 2-year school out of town and landed a Coast Guard license which would allow me to drive tugboats on the West Coast (see my other blog on that career change). http://backtoseawithme.blogspot.com
Anyhow, I have now completed the needed schooling to be a licensed Mariner and am picking up where I left off with regards to my passion for Vanagons and VW's in general.
During the 2 years in school, I purchased a 1984 Westy with the intention of keeping it and fixing it up, but then flipped it for some more school money.
About 3 months ago, I did some trading and picked up "Ferdinand", a 1982 Diesel Westfalia that needed a ton of work, but had great potential. He is my current project and he will most likely be the focus of my blog, but I'll be working on some other Vanagons over time and will highlight those repairs and modifications as well.
Ferdinand is up and running (before and current pics below), but he is far from being finished. Future plans include suspension upgrade, interior mods and engine swap as well as many other add-ons and upgrades.
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