Date:         Thu, 14 Apr 2005 12:07:07 -0400
Reply-To:     Roger Sisler <rogersisler2000@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Roger Sisler <rogersisler2000@YAHOO.COM>
Subject:      Re: WTB: coolant tubes

Hello,I have an 85 w/1.9.I had about 7 pinhole leaks at one time--without
the pressure cap installed.Looked like a water fountian,the kind one sees
in the park. This was when I bought the van.Turns out, only one pipe was
bad-the other, still perfect.Dont remember which was bad,as I replaced
both.I used plastic pipes from a 2.1. An 86 I believe.I made them fit,but
they wont without jerry rigging.I remember that I used a top radiater hose
from a Mazda 626 to complete one of the pipes to the engine.
The other needed just sections of straight rubber radiater hose.That was
25,000 miles ago.No problems to date.Cant say that for most other systems
on the vanagon.I also noticed that the power steering lines were corroded
almost through, so I replaced them w/lines from the same 86.Not hard to
do.Plain rubber high pressure fuel line can be substituted.I might have
used that , but I felt that I was pushing my jerry rigging habbit too far
already. The key is that the lines and pipes were corroded from the
outside ,to the inside.Only a short section of pipe was subject to this
corrosion, and the remainder was still perfectly smooth and clean on the
inside all the way up to the radiator.I have seen where people have cut out
this section and used a universial radiater hose as replacement(you can
walk through a junk yard w/ the cut out metal pipe and match it up w/ a
rubber hose from some car). Being a jerry rigger by nature and  mandated by
finances, this repair looked good to me-really they did.I was impressed
with the slick repair these people made.Especially with all the work that I
had to do to put the plastic pipes in.Why didnt I think of that, and just
skip the plastic? Duh? If one of your steel pipes is still looking good,
maybe you should keep it and replace the bad one only.The rubber extention
hoses from the front of the pipes to the radiater will also have to be
replaced with bigger in diameter hoses from a post 85 van ,if the plastic
pipes are used.A note here- plastic pipes for a 1.9 may be avaliable new,
or from a late 85 van.Check w/ a VW dealer, or Go Westy.These pipes will
fit a 83.5 to a 85. Not a 86 to 91.I got some used ,and will use them to
replace my jerry rigging when I get the motovation, and all these other
problems I have w/ da van are fixed.The gas tank must be dropped.This is a
great time to replace the gas tank rubber seals(be sure to also get seals
for the expansion tanks by the front wheels-VW dealer parts).Also, the
shifter probably could be accessed better at this time, and a shifter
rebuild would probably be in order for both me and you.Maybe you can see
why this is a big deal.Not expensive( $100 or $200 extra),only a lot of
work.You may check w/venders at the top of this page for pipes, but I
wouldnt spend $350 for 2.1 pipes that dont really fit.If you feel very
lucky,and the gods owe you favors, maybe your favorite junk yard will have
a couple plastic pipes for a 1.9.I wouldnt count on that. Dont waste your
time with new or used steel pipes.Used 2.1 pipes will work , but may try
you.With first hand hind site, I would say use the universal hose if you
cant find used 1.9 pipes.Another note- stainless steel pipes are sometimes
avaliable on Ebay at a good price. Roger