Date:         Tue, 13 Jul 1999 18:39:22 EDT
Reply-To:     Dagbear@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Rico Dagastino <Dagbear@AOL.COM>
Subject:      Re: '83-'85 Cooling Hoses
Content-Type: text/plain; charset="us-ascii"

  I have an 84GL and am looking for an acceptable way to replace the engine
to radiator hoses which line the engine compartment.  About a week ago, I was
driving home from work and the coolant warning light came on. I stopped the
van and checked the coolant level. One of the long hoses which crosses the
engine had begun to leak through a small hole.  I topped off the system and
drove to the Auto Zone in Millington (about 4 blocks away at that point) and
explained to the clerk that I wanted a hose to patch the system together so
that I could get home.  I explained that I knew they wouldn't have the
correct hose but that all I wanted was hose to connect the damaged ends of
the hose together.  All the clerk, who knew only to sell what the computer
told him, could say was, "I ain't got that hose."  Excusing myself, I drove
to the NAPA about 4 blocks away.  They were much more helpful.  They found a
hose with the acceptable dimensions but it would have to be ordered.  No help
in getting me the rest of the way home.  Again I topped off the cooling
system and drove to the hardware store about a half a mile down the highway.
After due and thoughtful consideration of all the fittings available in the
plumbing department, I opted for the simple approach. I purchased a 6" long
section of 1 1/4" copper pipe and two hose clamps. I was able to remove the
damaged section of the hose and replace that portion with the copper pipe.
After performing hose surgery in the parking lot of the hardware store, I was
able to drive the final twelve miles to my home in Munford.
  All of this serves as a prelude to a simple observation. The engineers at
VW must have obtained considerable satisfaction from producing a vehicle in
which so many of the hoses in the cooling system are of differing diameters
on each end.  This simple fact makes replacing them with locally obtainable
parts very difficult.
  That having been said, the greatest impediment to replacing these hoses
with locally obtainable and reasonably priced hoses is the necessity of
fashioning an adapter to connect the fitting which connects the transmission
cooler lines and the air bleeder hoses to the radiator hoses. Two options
present themselves as a solution to this problem:
    adapters can be fashioned to adapt the 1 1/4 "id hoses to the larger
diameter of the fitting for the transmission cooler/bleeder valve attachment,
or
    a suitable replacement can be fashioned for the fitting itself.
  As I pondered the challenges presented by each course of action, I felt the
warm glow of inspiration begin to burn brightly in my mind and I was filled
with the satisfaction which can only be felt when money is saved by finding a
way around a problem. I resolved to make a fitting to replace the plastic
fitting with the horrid connections of the bastard diameter.
  I spoke to the maintenance manager at our plant and explained the course of
action I had decided upon.  He said they could help me fashion an adapter to
replace the horrid fitting. It would be equipped with connections to attach
the bleeder line and the transmission cooler lines.  My heart leapt for joy.
This creation would allow me to use 1 1/4"id hose to join all of the hoses
and pipes in the cooling system.
  At this point the creation is still a dream shrouded the giddy mist of
euphoria which surrounds the act of creation.  I will send details of the
finished product as soon as it emerges from the crucible.  Until then I
remain forever yours. as you are, consumed with the joys of Vanagoneering.

Rico Dagastino
Munford, TN