My 79 Westy Bus to Ford 2.3 Conversion Log

Are you one of those confused people who can't make up their mind?
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fastmc25
Posts: 290
Joined: Fri Jan 04, 2002 12:01 am

Post by fastmc25 »

Hey metropoj


How have things been going? Have any time to work on the bus?

I decided to go ahead and mount my radiator in front........ I have the Mexi-grill and gave up on the rear duals........ The rads i have work in the back but i want more ram air cooling than they will afford. I plan on long trips in this thing so the ram air will be best........

Have you any pics yet of your up front cutting? I cut mine last night and cringed when i saw that low air duct you spoke of..... I know how i want this to work but wouldn't mind seeing others that have already been cut/done.....

I think i'm going for a removable front grill for servicing.... I want the rear boxwork to be permanent so the parking brake handle can be attached....

Please Enlighten us OH great cutter in the North....... :lol:
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
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metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

Hi Guys, thanks, I needed a little encouragement to get my ass in gear :) This is the part I hate about a project, it's the 'between time' when you have done only so much and then life takes over for a bit and you go into the garage and see this big pile o bus with a hole cut in the front and wonder why you started such a damn project :) ....


Paul, I'm glad Antonio was able to fetch you up that front rad grille from Meccico ! I've had good dealings with him and I'm glad I wasn't the exception on that one ...

Progress done since the winter .... ZERO :(

I've been side tracked with a basement reno and now the cottage season is here and my garage is now a staging area for a massive sort and toss Yard Sale to clean the place up ...

As God is my witness, I WILL take some pics of the front that I have cut out so far so you can see what I've done.

I will also post a link to KUSTOMKAMPER.com to see what this guy did for his V6 conversion with front rad, neato idea, I don't know how well it pulls in air though ....

I did something that is so ME it's sad. When I start these projects, I get sidetracked, and i decide to start rebuilding the front beam end to end, instead of getting the front mounted in properly ....

Engine is on the floor, with Esslinger adapter, I'll get it mated up to the trannt soon and get it IN the beast so i can start routing some 1.5" copper pipe up to the front and the heater core under the rear seat ....

Thanks guys for the patience, I've lost my way for a little bit ....
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fastmc25
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Post by fastmc25 »

Hey metropoj ,

I totally dropped the rear twin rad concept because i didn't like the way it looked and it took all of the engine bay to do it........as i said earlier i am doing the front mount now.
I went to a local salvage yard and found a 87 Caravan with V6. The rad does look like it will fit well between the front frame members. I went to PepBoys and ordered a new Rad for $69.00..... I'll go back and get the fan off the Caravan this weekend. :)

Basically my plan is to build the box behind the radiator as permanant. That way it will suport the parking brake and not be a nuisance to remove. My plan is to make the rad serviceable from the front outside. Remove the grill for coolant servicing and rad removal/installation...... :shock:

One thing i noticed while looking for a new type rad was 87-90 Ford Bronco II trucks w/2.9 V6 motors had a cool radiator. The bottom outlet was turned downward. The radiator will also fit our measurements for mounting under the grill. Something to look at......... :wink:

I'll photograph my progress and post for ya this weekend, especially since we have a common front rad thing going on...... 8)

Maybe it will inspire ya a bit..... :lol:
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

Hey Paul, good sleuthing. I see there are a couple Broncos at my local wrecking yard, I'll go take a boo at them .... you've got a hell of a ride planned there, it looks great !

At the front, and I know pics are worth a thousand words and I'm so damn slow getting to that, you mentioned about the rad fitting right between the ladder frame rails, exactly, that was a nice thing. I also liked the top fill of the rad on the Caravan 3.0l too.

I did something further in design. I notched out the front inner bumper support that runs just inside the nose between the frame rails to drop the rad down further and bring it closer to the nose, I swear I'll get some pics done. The thinking was this. I want to have the rad filler neck poke into the bottom of the fresh air grille chamber and can fill it from there. Also it's definately the highest point of the system :) .... Once notched out, the fits really nice in there and the filler neck will slide nicely in tehre too. I'm going to close off my sliced out fresh air ducting so I can still get some fresh air in there too, those cool air vents are so refreshing in the heat I hate to kill them. I also want to preserve my ambulance fans in the ducting too ...

Paul, if you want the matching black plastic fresh air grille to your rad, go to http://www.brazilshopping.com/store/pic ... astica.jpg I had no issues geeting my stuff from them and they were very helpful ....

These guys also sell smoked lenses, new taillight lenses and all kinda of stuff. I also ordered 2 smoked front turn lenses to kinda all blend in together with the grilles etc. i think it'll look cool ....

For inner shroud, we're kinda on the same wavelength. I am going to mock up some styrofoam SM for the shroud bubble on the inside, tape it over and fiberglass over top to make a shroud to enclose that all in, probably permanent too or at least sealed and attached to the floor. Rad will be accessed from the front by removeable front grille. I have only rough cut the opening so far, notched the inner bumper support and laid the rad in quickly. My other hope that my moving the rad up closer to the front by notching the support will be more room for the hot air to exit out the bottom of the opening ( and keep the emergency brake as factory operating as possible without doing something else ....

Anyone got a time making machine ? My 2 and 3.5 year old are taking up my fab time LOL .... Oh well. Thankfully, I will hopefully get most of my garage back for the summer after we have a huge garage sale this weekend !!. Then I'll strip out the van more and get that damned rad and engine / tranny up into the body instead of crying on the engine stand .... :( ....

Paul I think you will beat me to the finish line LOL ..... But we can at least bounce ideas back and forth .....

Inspiration is taking hold !!
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fastmc25
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Post by fastmc25 »

Hey metropoj ,

I worked on the rad today....... I posted on my thread about today's work...... Here is my take on the radiator mount.........Since we both are doing this same radiator maybe you can get an idea from my pics...

http://s71.photobucket.com/albums/i160/ ... 0mounting/


Peace,
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

Interesting stuff ! I see you notched out the bumper support, how clever.

You're doing some nice work Paul ! I have been hacking away without a plan so far, so we'll see how it ends up !!

I's also kinda neat to see how 2 individuals proceed down a similar design path ...

Hey, I FINALLY GOT PICS !!!

This shows how I notched out behind the bumper support to give me a little more rad clearance for height. The rad will rest down further and more forward than if I placed it on top of the bumper support between the frame rails.
Image

This next shot shows how much I gutted from under the dash. I'll need to refab the EBrake bracket at the top and plan to reconnect the fresh air inlets to whats left of the stock ports, i wanted to preserve the location of my Ambulance fans ...
Image


This next shot shows a frontal kinda shot to show the amount of material I cut away. I probably should have cut a lot shorter from where I did ( you can see the trace of the mexi rad position in marker on the nose. The previous Mustang rad was quite large and i started cutting based on that. Haste makes Waste .... :( You'll see the tabs there, I was planning to fold back the sheet metal to make some affixed points exactly where the rad grille will join at ...

Image

This next shot shows how much of the stock fresh air ducting I ended up cutting away. Without any real idea how I'd fit the rad, I sliced into the fresh air boxes, which i will close off as a smaller compartment to make them useful again. I then ended up slicing into the bumper support for the rad instead of cutting upwards ..... oh well ... I have a compelte spare nose in the back just in case I foobar something up completely LOL
Image


Here's another noseshot of the rad installed. I plan to move the overflow bottle to the right or left of the rad, not sure on gas pedal space at this point.
This allows the rad cap to be accessed from the outside from behind the rad grille, so I will enclose the interior by the looks of it too and not need to have access from there ...
The rad sits nice and high and little is cut off from air flow in this position. My other idea was to cut up into the frash air grille and let the rad cap poke into the fresh air grille betweent he 2 air flaps, that would be much better for air flow and kinda cool .. :)

Image

So, it moves forward at a snails pace, i hope to have the van kinda invading the whole garage shortly across both bays so i can start to gut some of the interior and stuff. While the vehicle is apart in this state, I will get the body media blasted underneath and fix up any bad areas before they get too bad .....
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fastmc25
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Post by fastmc25 »

Looks cool,

Thanks for the pics...... :D

After reading some of your earlier posts about cutting the front I decided to try and save the parking brake support if i could. That's why I cut mine like I did.

My only concern is still that the rad I selected will work well for my V6. The Caravan had a 3.0l and this rad supported it so it should support my 2.8l engine........ Especially with the extra water capacity of the long water lines. I'll be running the stock Caravan fan and shroud.

If this system fails the road tests then I have plenty of room to upgrade to a aluminum racing radiator without modifying the body further, which actually would be the better first choice........ Just cost more.

I work outside at my job and lately it's been so hot ( 103-107degree each day) that when I get home I haven't worked on anything.... :( ..... Hopefully this weekend I can finish the shroud work and permanantly mount the rad.......

Oh Yeah, I went ahead and ordered one of the vent grills to match.... :D

http://www.brazilshopping.com/store/pic ... astica.jpg
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

:lol: You gotta have the matching air grille Cool stuff ...

Esslinger makes a 2.3l hi output water pump that I think I'll pick up and install, you're right, that extra length to run water may need a little help to the front ... and a bigger rad ....

I am going to source up some 2 inch aluminum pipe instead of running copper like kustomkamper.com did. But, I am so far awy from that stage !!
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fastmc25
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Post by fastmc25 »

I think i'd be careful going too larger on the pipe...... The Esslinger pump has more volume but traveling that distance the pressure may be too low to effectively move water.... :? ... I was thinking of 1.25-1.50 max pipe....for mine.

You don't want the water to go too fast either otherwise you loose the heat sink effect of the coolant going through the radiator.

A friend here used top rail from a chain link fence....... 1.25" galvanized pipe and it worked well for him........ No problems.....

I even thought about a booster pump from Summit or Jegs to put in the line going to the radiator to help flow. I'll test without it first though.....

More to think about......... :)

Peace
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

You bring up an excellent point, the exit from the rad is fairly small 1.5" diameter, I should match that ...

I heard about galvanized pipe being used. I guess there is no corrosion of the galvanized material with coolant ?

I may do the same then. That seems a lot more beefier than aluminum...
Gerrelt
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Joined: Mon Sep 06, 2004 11:56 am

Post by Gerrelt »

metropoj wrote:I heard about galvanized pipe being used. I guess there is no corrosion of the galvanized material with coolant ?

I may do the same then. That seems a lot more beefier than aluminum...
Dit you allready read this?:
http://www.rjes.com/html/material_choice.html

Some interesting stuff about which materials to use for cooling systems.
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fastmc25
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Post by fastmc25 »

I read it...... I'll probably still use the 1.5" pipe....... Plastic would be great if i could find high temp plastic tubing.............except it would be susceptable to cracking and breaking.......... I can get steel pipe pretty easily locally.........probably .095 wall. ........... We'll see......

I'm not going to spend a lot of time doing studies on this... :shock: .. I'll absorb all the info i can find and make a choice...... Like Yesterday..... :lol:
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

Post by metropoj »

Finally back at it ! Now that my youngest is nearing 2.5 years and my eldest is not quite 5, the project continues onwards.

Just trying to refamilarize myself with the collant piping. mastfc, you used Galvanized and I noticed the article posted regarding galvanized. Since my Ford is all iron block, perhaps i don't need to worry about that galv vs. Zinc but I'll gave to check it out. Thanks for the info postings Gerrett.

Stripped out all the old heating pipes, found some more rust that needs attention ( sigh ) so off to get it soda blasted or soemthing underneath as the cross rails and floor are blistering yet rockers etc are still solid. get the battery tray and a couple spots also blasted up ..

Too bad, the underneath of the camper was undercoated very early on in it's life and 99% solid. I hate to disturb the undercoating and have to repaint the whole dang floor.


Gotta build a tow bar too and get it out to blasters while i finish mating motor to tranny and try to pick up from about a year and a half ago :( ...


Sloooowwwww going ........
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fastmc25
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Post by fastmc25 »

Any progresss??????? I'm anxious to see how things are going....

Peace,
Peace,

Paul

1973 Adventurewagen (AKA Clyde) V6 powered
1961 Deluxe Beetle (Christine)

www.fullmoonbusclub.com
www.arklatexvwclub.com
www.lovemybus.com
metropoj
Posts: 997
Joined: Thu Sep 05, 2002 12:01 am

back in the Saddle ( for a bit here and there )

Post by metropoj »

Well, after collecting some more parts, etc, and a new home built compressor, I am starting up with "The Boss" once again.

I got the tow bar mounted to the front of the van. I picked up a DIY Reese kit for 45 bucks that I attached directly into the front bumper support metal. I hope it is strong enough. if not, I'll slide some angle iron in behind for support.

For the next little bit, I'll assemble up the motor and tranny and get it all torqued and mated up. I plan to buy a reman 2.3l engine for it but I'd hate to buy it now and let it sit in the van while the 1yr warranty ticks away and never been started.

Paul, if you are reading this, You ended up using the 1.5" Galv fence pipe right ? You also mentioned getting a bead welded around the ends to keep hoses tight. How far did you run the pipe to ? I assumed through most of the body then you used long hoses to connect the rad and water pumps to the pipe ? Where did you get your long rad hoses from again ? I looked but didn't seem to find what I was looking for information wise.

Hopefully, before the snow starts a blowing, I'll at least have the motor installed ( gotta fab up the motor mounts ) and then start running the plumbing / rad / exhaust after that ....

I also gotta mount my rear heater unit under the seat and plumb that up too ...

Slow slow process :) .....
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