Date:         Mon, 31 Mar 2008 16:33:08 -0400
Reply-To:     craig cowan <phishman068@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         craig cowan <phishman068@GMAIL.COM>
Subject:      so it turns out i like vanagons.....
Content-Type: text/plain; charset=ISO-8859-1

Not to distract from the argument about how much we'd all love to buy an
$80K GoWesty vanagon and put no work into it ourselves, but i would like to
say that i have a problem. Problems, are what we have this forum for, we
post a problem, and those with more experience suggest solutions for the
problem. Well i've also been told that "accepting your problem is the first
step to solving it", i'm not sure if that's true, but here goes.
It seems i'm addicted to vanagons, and thoroughly enjoy them.

I'll give you guys all a second for that to set in....








Okay. Well as some of you know, I'm amongst the youngest of the vanagon
fanatics on our list, a college student that can safely say "is on a
shoestring budget". Furthermore, my vanagon's been NOTHING but problems
since day one. Just one after another. Between my $500 repair of a $2.50
exhaust gasket last summer, and working 10 hour days at minimum wage to fuel
my addiction, it seems i needed a solution. Well when my spring break plans
went sour, i decided "what better time than now". After taking account of my
finances, resources, and skills.....i undertook a project slightly too
ambitious for all of them. I decided i would be removing my engine and all
of its peripherals, and replacing it with another engine/peripherals from a
'known good' van. So after undertaking the ambitious engine removal using
only a bag of mix and match tools, a floor jack, and the basic idea that
"well i'll just unplug everything, and disconnect what seems obvious, and
all will be well", i pulled the engine in just 4 hours, with help for about
the last hour of actual engine lowering and man-handling of tough
components. There were endless reasons not to reuse this engine, most
noteably that it had signs of heads that would soon be leaking, half a drill
bit stuck and partially "drilled out" in one of the heads (and conveniently
at an angle..), more rusted on components than anyone could expect, and we
knew very little about the engine other than that it was "supposedly a low
mileage Canadian rebuild".
So the engine's out. That was such a wonderful feeling! As the next day came
along and i started removing peripherals, it was obvious that this engine
really shouldnt be reused....bolts were breaking left and right, major
systems were MISSING (NO throttle position switch system), and there was
just plenty of "retrofitting" throughout the engine. Either way, i kept on
truckin untill i had removed the heads with only little difficulty. Upon
inspection of the heads, and further inspection by experts....they proved
really really nice. No cracks, only minor pitting, no wear in the valve
systems....
So it was decided that the engine was going to be saved. This, was a
slightly uneasy moment for me, as it occured that this was going to cost me
more than just "putting in the other engine". Well the heads were rebuilt by
the machinists, the flywheel was cut, and all bolts extracted/helicoiled. I
spent an entire week of working 8-10 hour days on my car, getting the engine
"ready", and the car "ready to accept the engine". This included repairing
my steel coolant pipes, resealing the gas tank, replacing the heater valve
under the spare tire, and most importantly, fixing the clutch problems.
These problems were associated with a binding bell housing (which was
replaced with another bellhousing), and the transmission fluid's been
changed. Well this weekend, the reassembly began. My parts arrived from
their various vendors, and i hold Ken Willford in high regard for his
services in providing help and parts, in a timely and organized fashion!
Parts in hand and an assembly team established, we went at it. With a group
that we like to call "The PIttsburgh Vanagon Club", we got together and
built an engine/car! The heater valve was replaced and tweaked to
perfection, the odometer repaired, the clutch hydrolics system sorted out,
the engine assembled, and the perifferals bolted on. New fuel lines
throughout, fuel tank resealed and installed, coolant hoses replaced,
transmission filled, and it was all ready to go. Except, while reassembling,
it was discovered that my new water pump was defective, so assembly was
halted. Ken Willford from Vanagain has another in the mail, and all will be
well, thanks again Ken! So now after a 48 hour weekend home from college, in
which i worked between 24-30 hours on my van (depending on what you count),
eating only 3 meals and getting only 6 hours of sleep, i can now say that i
have an addiction, and i'm pretty good at it! The engine is as ready as it
can be with the parts we have, the car is the same, and in another weekend
of work, i'm confident it can drive away without problems for years to come!


So it turns out i really enjoy working on vanagons, and i'm pretty good at
it. I"m no longer afraid to "jump under there with a saw-zaw" if thats what
it needs, and i'm happy with what i've learned. Once again, i need to thank
the entire list, Walt Spak, Eric Zeno, David Milo, Brian Honan, Steve
Mancuso, and Ken Willford. There's no way i could have done what i've done
so far without them.

Yes, the engine's not in yet, theres no need to brag yet, and my fingers are
still crossed. But, i'm now confident in my own skills, ready for anything
to come, and hope to enjoy my vanagon for years to come. With body work,
this bad boy could be worth saving! So i guess the question is, how do i go
about finding a job involving vanagons? I could spend another summer working
for minimum wage to pay for vanagons, or i could spend a summer working with
vanagons......
Who needs to hire some cheap labor?!?     : )

Thanks again to everyone! Now, you can resume your discussions about $90K
syncro Westy's, who's tires are the best (my Hankook RA08's have worked
great for both miles i've driven on them so far!), and what the best way to
adjust the valves on hydrolic lifters. That is all, but thanks again!

-Craig
'85Gl