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 Tango Van - 1972 westy..

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Mon Nov 10, 2014 9:41 pm

Look up the prices...

Headers, heat exchangers.... affraid
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WizBizMartin
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Location : W-S-M
My Ride(s) : 85 Mexican Beetle, 20v T Beetle, Honda Xr125
Registration date : 2008-11-27

PostSubject: Re: Tango Van - 1972 westy..   Tue Nov 11, 2014 6:02 pm

good work Rich !
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Nov 11, 2014 7:13 pm

Meh! Had to replace both gaskets last night. Few hours work!

That and. Replacing vacuum hoses for brake servo. It's still taking too much / dropping the revs by 200rpm and is affecting the mixture... So may need to look ok at replacing the servo soon.

Test drive was to work in the morning! All fine.

Much better drive. Oil temp was noticeably lower - combination of exhaust sealed properly and manifolds sorted!!

Running at around 90deg C.

Pics later
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Mr Scoops
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Male Number of posts : 37904
Age : 43
Location : Weston super Dooper
My Ride(s) : 1971 Patinaed Early Bay: 2011 A3 S-Line
Registration date : 2006-08-19

PostSubject: Re: Tango Van - 1972 westy..   Tue Nov 11, 2014 7:29 pm

I'vd got a remote servo here I'm going to be flogging soon

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Nov 11, 2014 10:59 pm

hmmm Question
will have a think scoops.. ideally looking to mount it in same place as current stock servo, however using a Brazilian bay set up inc new master cylinder.. saves having to sort new brake pipes etc..
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Nov 11, 2014 11:19 pm

So...
As it was raining etc.. decided to try to get the bus as close to the garage as possible


Just happened to have some spare inlet manifold gaskets in stock


Did the offending right hand side carb first.. bit of a pain, as chose to do it all in the engine bay as to avoid fuel spillages etc.. also quite worrying was how easily the nuts came off.. not that tight at all..


Removed old cracked gasket and plugged the inlets to avoid crap getting in as cleaning off manifolds.


Had to piece the broken gasket together to make sure nothing was missing..


All cleaned and new gasket fitted..


Next was the left hand carb.. thought I'd better check it all whilst there..


Just as bad.. but not completely blown yet.. fell apart as soon as I moved the manifold away from head..


Replaced the vacuum connecting hoses to the balance pipes as had to undo them to move the carbs around.

All back in by midnight (started at 9pm ish) so not bad.
Test run was on the way to work.. had no engine temp reading on the gauge.. worked out I'd lent on the dipstick sender connection and had to replace the spade connection at work.

Engine running much better.. some slight pops at idle, but it was set up with a leaking header.. so needs a tweak. also have idle rpm a touch high at the mo.

However, on a better note it runs much cooler now!
After 25mile trip back from work in rush hour bristol traffic and 45-60mph on A38/A370.

Would normally be over 100 deg C..

Also, missed driving this bus in the dark/rain.. no intermitant wipers.. poor headlights (even though they are upgraded clear lens' euro sealed units with H4 lamps.. so main beam is essential at times.....

but love my blue led dash light mod I did a few years back Very Happy
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vietnam
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Male Number of posts : 1671
Age : 28
Location : Bleadon
My Ride(s) : 07 Golf, t25 devon
Registration date : 2011-01-04

PostSubject: Re: Tango Van - 1972 westy..   Wed Nov 12, 2014 9:27 am

Looks like its been fighting all the way Rich - good to know its back fit and ready to go though Smile
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Sun Nov 16, 2014 7:15 pm

Yep.. Still fighting... Popped header off again. Got some fire gum paste to apply up by the copper gaskets. Need new 11mm outer diameter exhaust nuts.. Brass ones aren't tough enough! And a gasket for the muffler!
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue May 26, 2015 8:39 pm

So...

Time to sort this again...

Jobs to do:
Brazlian bay servo install as the stock servo has had it! This is not a straight swap...
New master cylinder to fit
New front to rear metal brake pipe to fit
New front brake flexi hoses to fit

Engine out
New pushrod seals to fit
New ht leads to fit
Need to make and fit new choke blanking plate gaskets
Oil change and new filter
Re-check and fit exhaust header with engine out. Still not sealing right
Plugs/valve clearances to set
Clean an re-paint tin wear and fan shroud
Clean and re-paint firewall
Clean and check starter solenoid
Put it all back in Wink
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Road Rage
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Male Number of posts : 4830
Age : 44
Location : Highbridge
My Ride(s) : 1972 Bay; Shitroen C4
Registration date : 2008-04-28

PostSubject: Re: Tango Van - 1972 westy..   Tue May 26, 2015 9:43 pm

powder coat the tin and firewall
worth every penny

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Sometimes even Volkswagen get it a bit wrong the first time

Even split screens had high indicators Wink

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Mr Scoops
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Male Number of posts : 37904
Age : 43
Location : Weston super Dooper
My Ride(s) : 1971 Patinaed Early Bay: 2011 A3 S-Line
Registration date : 2006-08-19

PostSubject: Re: Tango Van - 1972 westy..   Tue May 26, 2015 9:49 pm

120 for my tinware and firewall to be done at Nailsea.
Inclues media blasting and powder coating

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Fri May 29, 2015 2:19 pm

Jobs done so far...
Brazlian bay servo install.. inc new bracket made up
New master cylinder to fit - new front brake lines made up also.
New front to rear metal brake pipe fitted (for the brake servo hardline.. couldn't remove the old one so found some spare OG holes in the cross members - very tight fit and then primed and painted up in place)
New front brake flexi hoses to fit, inc new tabs and hard lines to the callipers all done
Fitted new vacuum hoses and non return valve: now no leak in the system and engine holds revs under servo.

Discovered: old feed pipe to m/c reservoir had no seals and was split, and remote reservoir was split in the bottom - enough to absorb moisture into the fluid.
Both ordered inc new seals and clips...

So: refit pipe and reservoir and then bleed brakes again on Sat morning... still air in the system)

then.

Still to do..
Engine out
New pushrod seals to fit (bought)
New ht leads to fit (bought)
Need to make and fit new choke blanking plate gaskets (bought gasket paper)
Oil change and new filter (bought oil, need to get filter)
Re-check and fit exhaust header with engine out. Still not sealing right (bought new copper gaskets)
Plugs/valve clearances to set
Clean an re-paint tin wear and fan shroud (bought etch primer and paint)
Clean and re-paint firewall
Clean and check starter solenoid
get x2 new front tyres as walls are cracking
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Mr Scoops
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Male Number of posts : 37904
Age : 43
Location : Weston super Dooper
My Ride(s) : 1971 Patinaed Early Bay: 2011 A3 S-Line
Registration date : 2006-08-19

PostSubject: Re: Tango Van - 1972 westy..   Fri May 29, 2015 4:30 pm

Fook!

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Jun 02, 2015 10:29 pm

Eyelids removed and chrome all cleaned up. Also refuted the stainless grill and tidied up edges
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Jun 02, 2015 10:31 pm

Made my own hotstart relay setup

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Jun 02, 2015 10:34 pm

Servo removal








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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Jun 02, 2015 10:36 pm

Full of muck and rust inside servo. Brake reservoir full of muck and master cylinder knackered. Needless to say replaces all front pipe work and fully flushed out hardline to rear. Rear pipe from t piece already been replaced when I did brakes back in sept.
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Tue Jun 02, 2015 10:38 pm

New Brazilian servo and m/s
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:12 pm

Bracket sprayed up


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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:23 pm

Had to drill out original servo braket on the beam as new bolt pattern was smaller. This placed it too close to the edge so mad up some sandwich plates..



Made some spacers also behind the old bracket to ensure bellows don't pinch

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:30 pm

Brake rod connected and thread / nut all cleaned up.


Brake reservoir cleaned out and fitted up
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Mr Scoops
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Male Number of posts : 37904
Age : 43
Location : Weston super Dooper
My Ride(s) : 1971 Patinaed Early Bay: 2011 A3 S-Line
Registration date : 2006-08-19

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:34 pm

Good work Squire.
I took the Mrs's Bug to Gonzo and then to the Failand for dinner.

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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:45 pm

New front brake lines all made up and new flexi pipes fitted








Also fitted all new hard line for vacuum pipe from front to rear of bus and painted up under chassis. Also new servo flexi brake pipe



In etch primer here so you can see it, but then 2 coats of satin black and lacquer to try and protect it





Last edited by tango_van on Wed Jun 03, 2015 9:33 pm; edited 1 time in total
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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 8:59 pm

All fitted up and bled.. Cheers Wizpop for your brake pedal skills, but then no pressure and fluid leaking out under master cinder!!!

Turned out that the feeder hose from remote reservoir was damaged and had a seal missing.. Also when removed it all that had a split in the base so was absorbing moisture etc...

So had sat delivery of parts from heritage and then all replaced and bled.. New pipe was wrong moulded shape, so had to heat it up gently and reshape it.
Old:






New!!!!


Next to each other



But of a pig to fit but all in





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tango_van
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Male Number of posts : 2846
Age : 36
Location : Wsm
My Ride(s) : 1972 Westy Camper Van, 09 Newbie 1.9tdi, Audi A4 B7 S-line
Registration date : 2006-10-11

PostSubject: Re: Tango Van - 1972 westy..   Wed Jun 03, 2015 9:22 pm

Friday night is... Engine out for new pushrod seals and a service, new leads etc...
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