Picked up a Caravelle

mackaymanx · 2011-05-01T12:14:24+00:00

Just got myself my first kombi, been sitting at a mechanics in Bowen for the last six months and finallly got around to asking about it. Now it's mine for $1100! This is how I found it. And this is why I got it so cheap, one dead motor.

live2surf Learner Dubber

5 posts · joined Apr 2011 · 7 Jul 2011, 3:23 pm

#850434

Awesome Brent, your bus is really coming together! Well done.

mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 7 Jul 2011, 5:06 pm

#850454

Trial fitted the SmallCar sump oil pickup and was not very impressed with the fit. With one side of the flange on the block there is quite a gap on the other side. This is a critical part that must seal properly to prevent air sucking into the system. I'll trim it down to get it to seal but it pisses me off that I have to.

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MickH Hairy Gutted Sloth

3,389 posts · joined Sep 2003 · 7 Jul 2011, 5:49 pm

#850463

now thats not very impressive..........👎

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 7 Jul 2011, 6:34 pm

#850484

2nd sump should turn up tomorrow so I will compare the oil pickup for that with this one.

Quote of the week
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Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 7 Jul 2011, 10:40 pm

#850570

Yeah Skot,in the T3 after you remove the tin ware you could do it in the vehicle.
You dont want to do this after you have just finished your conversion.
I have manged to stop the leaking head.
I will let you know how when I see you next.
With yours, do the heads mate,then no worries.
She stops well now!😂

Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 7 Jul 2011, 10:46 pm

#850574

Brent,check the clearance between the sump and pick-up too.There is reports about the early SC sumps not having suffient clearnce causing starvation.
BenC

mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 8 Jul 2011, 8:21 pm

#850743

Well my 2nd sump turned up today and the oil pickup fits, I had to take a file to it first but it fits. KEP automatic adapter I ordered came with the sump, these are very well machined 👍 . Made up some tools to torque the pulleys properly with, crank one worked well but the timing pulley one needs tweaking.

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MickH Hairy Gutted Sloth

3,389 posts · joined Sep 2003 · 9 Jul 2011, 11:08 am

#850858

Hey man......u know yer engine is upside down.....🤘

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Scottkombi Officially Full-On Dubber

358 posts · joined Dec 2008 · 11 Jul 2011, 11:26 am

#851163

Just a matter of interest - why did you go for the adapter ratehr than the bellhousing replacement? Aparently the VW flywheel is heaps lighter and hence using it means you engine torque will suffer.

88 Caravelle Syncro Camper
89 Caravelle GL microbus - 5 speed
69 Microbus
05 Mk5 Golf 1.9 TDi DSG

Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 11 Jul 2011, 11:30 am

#851165

I think the vv is 9lbs,subaru 11lbs

mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 11 Jul 2011, 1:56 pm

#851183

Scottkombi wrote:Just a matter of interest - why did you go for the adapter ratehr than the bellhousing replacement? Aparently the VW flywheel is heaps lighter and hence using it means you engine torque will suffer.

I'll clear this up, the adapter plate (auto) is for for my notch. The caravelle will be getting the bellhousing. I just got everything in one order

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 21 Jul 2011, 2:17 pm

#852894

SmallCar sent me a replacement oil pickup tube, it's better than the last one but the alignment is still not good, service was good thought.

Picked up my coolant manifolds today, I've gone two different ways to do a comparison. Here is the the first one with the manifold reversed, bosses welded on for sensors, outlet sectioned and welded.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 21 Jul 2011, 2:19 pm

#852895

one more

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 21 Jul 2011, 2:29 pm

#852897

Here is the second option. The manifold is not reversed, outlet is removed and pluged, outlet is then rewelded onto the other end.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 21 Jul 2011, 2:30 pm

#852899

one more

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 21 Jul 2011, 2:35 pm

#852900

Some side by side shots.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 24 Jul 2011, 7:21 pm

#853523

Manifold installed with the coolant bleed off hooked up. Earlier T3 coolant temperature sensor installed in place of the subaru one, this will let the temp gauge work properly in the dash, tapped this out to the correct M10x1.0 thread.

Edit - if yor wondering where I got the barbed elbows that are silver soldered into the coolant pipe you can salvage these from a subaru fuel filter.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 24 Jul 2011, 8:41 pm

#853533

This is the spacer you have to install under the dipstick when use the smallcar sump. Have to admit I got caught with this and it was a pain getting the dipstick tube in and aligned properly. Tube needs to be tweaked a little and would have been easier to do when I had the timing covers and pulley off doing the cam seal. Spacer ended up being about 15.5 mm high.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 24 Jul 2011, 9:23 pm

#853536

Bit of minor clearancing between the sump and water pump. This is needed for turbo pumps (which I am using) and the later subaru pumps. Engine mount also needs some work.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 25 Jul 2011, 6:18 pm

#853670

Shaved a bit off the mount bolt head, gets a bit tight around the pump.

Filed back this casting flash on the bellhousing as the header were touching. Will end up with a bit more space as the headers were trail fitted without gaskets.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 27 Jul 2011, 3:38 pm

#854031

Machined up some blanking plates for the coolant manifold. Then frankensteined this together, filled the manifold with water and pressure tested it to 30 psi (about twice working pressure). No leaks on this one.

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Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 27 Jul 2011, 10:30 pm

#854123

Good work.Those headers dont stay shiny like that for long,unfortuantly.
Just a thought,have you seen the Tom Sheils thermostat housing.This may give you more clearance.
Have you made a coolant by-pass yet,dont be tempted to make one from plastic tees.
BenC

mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 4 Aug 2011, 8:14 pm

#855415

Yes I have seen the Tom Sheils thermostat housing, coolant bypass is built into the manifold.

Quote of the week
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Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 4 Aug 2011, 9:49 pm

#855454

Are you going to run your heater?VW and Subaru coolant flows in opposite direction.

MickH Hairy Gutted Sloth

3,389 posts · joined Sep 2003 · 4 Aug 2011, 10:16 pm

#855458

Ben386 wrote:Are you going to run your heater?VW and Subaru coolant flows in opposite direction.

But they both flow towards the front of the car😂😂

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Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 5 Aug 2011, 3:20 pm

#855520

You know what I mean Mick🙅

Adsman Officially Full-On Dubber

393 posts · joined Jan 2007 · 5 Aug 2011, 9:43 pm

#855585

looking good Brent 👍

What my garage isn't messy........Well chaos is a form of order isn't it?

mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 18 Oct 2011, 3:51 pm

#867553

Small update.

Machined up a wedge for between the throttle body and the intake manifold. This should give me a better angle and more space in the engine bay. Scavenged and modified this from the original subaru motor intake manifold.

Also replaced the plastic fuel fitting in the engine bay.

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mackaymanx Custom Title Time!

1,611 posts · joined Jan 2006 · 27 Oct 2011, 6:19 pm

#868960

Ok, finally some real progress!
Lost quite a bit of time getting over a bad back 😠 but mobile again now👍

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Ben386 Officially Full-On Dubber

244 posts · joined Apr 2010 · 27 Oct 2011, 8:36 pm

#868993

Looking good mate.
Glad I did mine on a hoist.
Clean up and paint the tin ware,makes it all look mickey mouse.😎