VW

First Blood

New Tire

I picked up my new tire today. During the process of putting it back on the bus, I managed to slice my hand.  I’m sure my dad would agree that its not really a project until you are bleeding a little, and this is officially first blood for this project.

After looking at the current tires on the bus (all four are different brands and sizes…), and doing some research online, I ordered a Hankook RA08 from Wal-mart Site-to-Store.  It looks like the tires need to have specially reinforced sidewalls, but yet be small enough to still fit in the wheel well (14” tires).  WMT had the tire I needed online, and they were able to put it on the rim and balance it.

It was quite a struggle to get it back on the bus though.  If you can see from the pictures, the tire actually sits up inside the wheel well.  As hard as I tried I could not fit that thing back on the mount.  I kept cranking the bus up higher and higher, and each time it sort creaked ominously!  Finally, it was up high enough that I could wiggle the whole tire into the well and fit it over the bolts.  Success!  Of course I then lowered the bus too fast, and it came bouncing down and almost killed me, but it’s all good.  I’ve now replaced my first tire, and the bus is mobile again (even though I still don’t know how to drive it – I’ll get there).

New Tire Bus

I’ve also noticed the real wheels have a decent amount of positive camber (they bow out at the top).  I know VW’s have independent torsion bars, and are supposed to be slightly positive, but I’m not sure by how much.  Another future project for sure.

Bus Rear Cambered

Also, did you notice the brand new brake drums?  I didn’t know they were there when I bought the thing – Sweet!

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Oops!

Broken Key

I broke the key. GREAT. That’s just awesome.  Key broke-off right in the ignition.  Oops.  I managed to get it out using a thin steel pick, and I have a spare key so we’re good – It doesn’t look like the big box hardware stores can make me a new key, so I might have to call a locksmith.  In the mean time, I’ll be more careful!

 

Also, the driver’s side rear tire lost all air pressure at some point, and I’ve got the bus propped up on the jack.  Looks like I’ll need to special order a new tire.

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How does she know that?

New 9Pin

Turn Signals work.  Well not really, but it was fun to stay it with so much confidence.  The replacement 9-pin relay I ordered from Wolfsburg West arrived, and I happily plugged all of the wire connectors in hoping for the best.  When I turned the key and flipped the blinker switch down, the driver’s side turn signal started flashing regularly – Success!  When I flip the switch up, the passenger side flashes, but its twice as fast.  So not a total success, but still they light up!  I’m going to clean/ replace the rest of the connectors to see if that solves the flashing problem.

 

After testing the turn signals, I pull the emergency flasher switch.  Bam! I hear a popping noise and everything shuts off.  GREAT.  That’s just awesome.  Once again, I’m pissed, probably threw a few things around, cursing this dumb bus.  I think I blew the brand new 9-pin relay, and in the process fried the rest of the electrical setup.  I’m so pissed that I just need to take a break.  Stupid bus.

 

Enter Noelle; when I go back inside and tell her all about my troubles she gives me this weird look and says “did you check the fuses” … I’m like – “um … no”.  First off – how the heck does she know about fuses, second off – of course that’s the problem, and as soon as I replace one of the 16amp fuses everything lights up again, third – if she’s so smart why doesn’t she get out there and fix that thing up instead!  Anyways, I’m going to keep working on the turn signals, and try to figure out why the emergency flashers are shorting out.  Fun times!

Fuses Close 2

 

VW

Spring Cleaning

Finished Middle 2

More progress, more projects. This weekend I had an epic battle with the bus spiders; I fired up the engine for a while, and watched it run with my new friend Leo who owns an air-cooled bug and lives in the area; I drained a few more hours into electrical work, and started making a list of parts purchases I will be making soon enough.

My bus came set up as a transporter with a full bench seat in the back, and a 2/3 middle seat.  I don’t think they are original, and are probably not 1967 because they don’t have the handles across the top that identifies that year’s seats.  I won’t need them for the camper conversion, so I’m hoping to sell them at some point.  However, before I can do that I need to get them out of the bus and cleaned up… starting with the middle seat. I mentioned the intrepid bus spiders in an earlier post, and the middle seat is their home base.  From the pictures you can see that I have an infestation.  I was able to get the seat out of the bus easily enough, and set it up in front of the garage.  What followed was a few hours of cleaning out decades of spider nest and squirrel poo – fun times!

Seat NestI started by soaking the seat in spider killer,  then just starting cutting and pulling the fabric off.  I had it about half-way done when I first spotted her… the mama spider…  This thing was huge and as soon as she realized I had spotted her, she dug her way deeper into the filth.  I kept going, and eventually got most of the debris cleared away…That’s when Mama came back out.  This time she crawled up to the top of the seat and just stared at me.  I apologize to all animal lovers out there, but this was a battle fo real.  I grabbed the rubber mallet that I just happened to have lying around, swung at Mama and… totally missed.  She falls to the ground, starts scurrying back towards the bus – I’m screaming (probably at a fairly high pitch), and finally ended things with a solid stomp on the garage floor.  Mama spider is dead and I am now able to claim the rest of the bus as rightfully mine!

Spider Staring

On a lighter note, I found this tool buried deep in the nest.  I figured it was valuable because it was heavy and had “Germany” stamped on the side – I know, my immense intelligence sometimes amazes. Turns out it is a Hazet 2595 clutch cable adjustment tool, is worth some money, and is supposed make adjusting the clutch mechanism much easier.  Sweet!
Hazet 2595

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Wiring Fun pt. 2

Bus Lights Front

Headlights work.  That picture above reminds me of some creepy VW nightmare that I’m sure I’ll be having before this thing is up and running. This is another great story of the randomness that has made this project both fun and slightly unnerving. A few hours spent reading the wiring diagram, a while to figure out how everything connects, some more time spent cleaning the relay pins and connectors, hook it all back together and… nothing. no turn signals, no brake lights.  The relay clicks regularly when I toggle the turn switch, but nothing lights up.  The bulbs are brand new, and as a test, they light up when I touch the vl/ vr wires to the 30 wire coming from the battery.  I’m thinking its time to get new relays!  Before I cough up the cash for the big 9 pin relay, I was able to find a suitable replacement for the headlight dimmer relay at NAPA.

I bought the headlight relay yesterday, and after another trip or two to NAPA, modified the relay with a wire bridge per the instructions, and installed it in the bus.

Bus New Dimmer Relay

When I pulled the switch, I heard a small spark and the driver-side headlight came on. Partial success!  The lazy side of me wanted to call it good, but I kept messing with it.  As soon as I turned the lights off and tried to turn them on again, I got nothing.  I used the test light to make sure the relay was getting power, but the lights wouldn’t come on.  I figured the connector head on the wires might be too rusted (even though I cleaned them yesterday), or maybe that spark had fried the relay.  Either way I’m a little pissed, and so I do what I do when I get pissed and start banging things around, pushing buttons, and generally throwing a little tantrum.  During this episode, I was prodding and poking around with the test light, and accidentally shorted the live 56 wire with the yellow 56a wire leading to the headlights.  A big spark this time, and both headlights came on bright.  Success! The headlights are now in functioning order. Once again, I have “fixed” something on the bus by bumbling around and getting lucky.  At this rate, I’m going to have this bus out on a road near you any day now; just need to get the turn signals working, brake lights, engine generator, windshield wipers, e-brake, and most likely a lot of other things done first.  I’ll keep you posted!

Bus Lights Top