Ok we are back from our trip and it's time to file my report from Colins visit.
So originally I had two good running buses that I was going to tune up and address a few relatively minor things. However, about a week before Colins visit, Bus 1 developed a heck of a knock in the engine. Strange knock because it would go away after about 30 seconds of running. I still haven't taken the engine apart to see just what it is but the engine is out of the bus and in my shop now. I will be tearing it down over the next couple of weeks to see what the deal is. In the mean time I ordered another 1600 dp long block from Headflow Masters. I know some had issues with his builds and even I had an issue with the first one right off the bat but sent it back to him and he rebuilt it again and it's been in Bus 2 working fantastic and now has about 27k miles on it. No leaks and has really been great. He has been good to me and so I remain loyal. The new long block gets shipped out today so I'm excited to get it and put it back in Bus 1. I also sent Volksbitz a german 34 pict 3 carb to rebuild for it and everything else is new on it, generator, muffler, intakes, even a new awesome powder coat thermostat. I hope to have it up and running in a week or so.
Back to Bus 2 and what we accomplished.
I had a nasty sounding clunk in my wipers of Bus 2. I figured it was just loose nuts on the shaft or something. I never even looked at it but sometimes it helps to have some help to get things done. So we took out the glove box and wiper arms and started to trouble shoot just where the clunk was coming from. The shafts were tight and event the sealing grommets looked ok to me, however Colin just happened to have a new set of grommets in his stash that I still owe him for that we used when we reinstalled it. So after more wiggling, pushing and pulling we took the whole wiper assembly out and started to take the motor apart as it seemed the play was in the motor. Well in the wiper motor there are a couple of gears. One is just a larger circular gear and one is a spiral (?) gear, not sure what you call it. But there is an adjustment on the gears to tighten up the play, it is like the adjustment on the steering box, a set screw and a locking nut. Mine didn't have the locking nut on it and so it worked itself loose over time. We made the adjustment and put it all back together, cleaned the shaft splines with a razor (I would not have known to clean the splines, they looked just smooth to me but cleaned up nicely). Put it all back together and bingo, works great and no more clunking ( had a small rain squall in Jasper and was able to test them out).
Second on the list were my brakes. They start dragging after a while and the pedal was right at the top with no play and I knew it just wasn't right. I was going to be all ready for Colin and have the bus jacked up and rear wheels off so we could address the brake issue efficiently but I didn't get to it before he arrived. Colin noticed a "crunchy" feel to the brake pedal so we took off the protective pan cover under the front of the bus and started trouble shooting the brake issue. Well a little grease here and a little there and bingo, the brake pedal wasn't returning all the way and therefore they would drag just a bit. But greasing up the pivot points in the pedal did the trick. Way easier than pulling the wheels off etc. Again I was about to head in the wrong direction and do a lot more work than necessary.
(side note, I did end up taking both rear drums off because there was a new funny noise and feeling coming from the brakes and I did have one of the clips fall off and was getting caught up in the drum. It was worn down in thickness to about half but I put it back on and it seems to be just fine now.)
So while we were down there greasing up the pivots in the brake linkage we also greased up the gas pedal linkage and then Colin noticed I was missing a shift bushing. I had no idea.... well he just happen to have one of those in his stash too! (I still owe him for it as well). Now it shifts with even more noticeable precision.
We also timed it as it was advanced a bit too much. It really is running so sweet now. Brakes are perfect again, wipers are quiet, all the linkage is thankful for the lube and my brain sucked up as much knowledge as it could for one day.
We also discussed pulling out the windshield to go after some rust... next year. Bus 2 looks pretty easy, Bus 1 will need some rust repair. I'll get a couple of windshields and another seal and be ready to go when next years date gets worked out.
Also got to take Cloe out for a spin and whoa, what a treat. No rattles, clunks, squeaks, doors shut so quietly. Interesting to feel the difference between the single port power band compared to the dual port. It's subtle but it there. I think the dual port had a bit more top end power but the single port seems to have great torque. (I might me making all that up but at least that's what I think I felt.) It's really cool to be able to drive one of these that is so well sorted out and not a camper with all the squeaky cabinets. I think it's about as close as you can get from driving one of these off the lot when it was brand new.
So another year of great info, teaching and dialing in the Bus (2) and I'm already looking forward to next years visit and hopefully by then I have two reliable and well running buses again.
Now just a quick update on things after the visit. I've put almost 4k miles on Bus 2 in just less than a month. Fully loaded with people, camping gear and bikes. Our Whistler/Jasper/Banff trip was 2,433 miles. I did one points adjustment mid way through the trip. At times we had 4 kids and 4 adults carting around to different hikes in the Bus. I had a throttle return spring break in Vancouver, BC but was able to bend up another coil and continue using the same spring, still working just fine. Otherwise just no issues at all. Bus 2 has really needed nothing in the last 3 years of use other than a few tweaks and general maintenance. I pulled it from a 15 year slumber in a field in eastern Washington and spent a winter sorting it out and it's turned out to be an amazing and solid bus. I've put a total of 28k on it and about 27 k on the Headflow Masters engine. So far it feels like it has lots of life left in it. I will continue to pile on the miles and see just how much more I can get out of it. I know the trips I do and the loads I take are taxing it pretty hard but it's taking it like a champ.
This was our 8th year of taking a good road trip with the kids and it is just an awesome experience to watch the kids grow up with the Bus and get the routine so dialed. They are true veterans now and I'll keep this up as long as I can get them in the Bus.
Thanks again Colin, your service is very much appreciated and helps to keep the dreams as well as the VW alive.
I will have to add some pics but I only took two of the visit and one of them looks just like Colins photo.