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Date:         Tue, 16 Jan 2007 00:31:57 -0800
Reply-To:     Zoltan <zolo@FOXINTERNET.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Zoltan <zolo@FOXINTERNET.NET>
Subject:      Re: Boston Bob engines - Use caution
Comments: To: DanielCRoberts@AOL.COM
Content-type: text/plain; format=flowed; charset=iso-8859-1; reply-type=original

It is easy to overheat an engine when new. Especially such a well built one that Bob makes. I was sad to learn of the belt breaking and the eventual demise. We also learned from the story and feel with you. Bob, or anyone for that matter, don't install with glue. Sealant, that is recommended, yes. For a non mechanically gifted, it can be real frustrating and puzzling to own a machinery that is delicate and even known to be having its own personality sometimes. Little oil drips we don't mind and an oil plug to fix is not even discussed here, being just too simple and not worthy of making it an issue. Wait 'till you have some real electrical gremlin that you are trying to figure out for years. Dan, we know what it takes to own one of these vehicles. One has to be alert at all times. It is a learning experience from the first day on. These vans will teach you a lesson for life. They will make a man out of you. Although you had an expensive schooling, don't give up ever. It will be paid back many times over in the years to come. The pain will not be felt, the smile will be bigger, like nothing ever happened. Almost all of us go through similar things at one time or an other. When it happens to you, you think it only happens to you. We can all tell our stories of the same kind we had sometimes in our life. We too learned, and now that we are older with all those experiences, are not likely to repeat it. Let's hope, it will not happen ever again to you. Happy New Year! Zoltan

----- Original Message ----- From: "-- Dan Roberts" <DanielCRoberts@AOL.COM> To: <vanagon@GERRY.VANAGON.COM> Sent: Monday, January 15, 2007 8:09 PM Subject: Boston Bob engines - Use caution

I relied on recommendations from this List and chose Boston Bob when I needed a rebuilt engine. Unfortunately, the results were disappointing.

The Boston Bob rebuilt engine was installed in my 89 Camper GL (2.1 Liter) last spring. Almost from the beginning I noticed oil leakage from the oil drain plug and from the front and rear of the engine. The leakage was disappointing but at least did not seem to be severe when I left for an extended trip to southeastern US.

Prior to the trip, I talked with Bob McDonalds (Boston Bob) and he assured me the leaks would probably dissipate over time as internal engine pressure lessened with engine wear. However, when I returned from my trip, my own mechanic examined my engine and showed me that both front and rear main seals had substantial leaks, as did the oil plug.

I contacted Bob McDonalds again. He again suggested the problem might be with internal pressure related either to tight piston rings or to a collapsed engine gases recirculation tube (his speculation). He eventually sent a new rubber tube although my mechanic had assured him and me that the existing tube was OK. I installed the new tube anyway. He also sent several different oil drain plugs and several different oil drain plug rings.

None of the drain plugs or drain plug rings stopped the oil leakage from the oil drain plug. The oil drain plug still leaked, as did the front and rear main seals.

I sent an email to Bob asking him to provide some compensation for the oil leaks and their effect on the value of my Vanagon. He did not respond to my email.

Next, while traveling in Colorado, the engine overheated when the alternator froze, breaking the belt that also supplies the water pump. I pulled off the road and turned off the engine as soon as the coolant trouble light came on. (However, the alternator trouble light had come on about one minute earlier and I did not pull over and stop as soon as that light came on.)

I examined the engine and saw what appeared to be a blown front main seal. A subsequent examination of the engine by a 30-year Vanagon mechanic in Colorado confirmed my suspicion. Of course some would argue the fault was mine for not immediately turning off the engine when the alternator light came on. However, a subsequent investigation by the Colorado mechanic revealed that both front and rear main seals (head gaskets) had been improperly installed.

Both front and rear main gaskets had a large amount of glue over the entire inside grooves--facing the engine. As a result, when the glue had dried, gaps were created, thereby allowing oil to push through the gaps. The Colorado mechanic said that the gasket failure was inevitable, given the way the gaskets were installed.

Boston Bob has refused to respond to my subsequent emails in which I asked him to take responsibility for the leaking oil and subsequent blown gasket.

Replacing the improperly installed seals cost me about $1,500. Of course this does not include the motel bills when I was stranded in Colorado for 12 days. Fortunately, I can say the front and rear seals no longer leak after being properly installed. The oil plug still leaks.

This situation has been disheartening, as well as costly. I had been pleased to obtain a Boston Bob engine. I thought I was dealing with a reputable mechanic. Unfortunately, Boston Bob has refused to stand behind his product even though I can document and prove the engine was rebuilt with a substantial error.

Because of the error and because of Boston Bob's refusal to be responsible for the error, I suggest other List members use caution when considering whether to purchase a rebuilt engine from Boston Bob.

Dan Roberts

CC: Bob McDonalds

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