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on the road again...

10/10/2022

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A big hit for Willie Nelson, and also a happy event to be on the road again with our 1977 Volkswagen Transporter/Bus!  We call her Lucy.
What started out as a repair (see the post directly before this one) turned mostly into a top end engine rebuild.  The work is now complete, with the engine back in its place.  The test drives have been strong and smooth.
Here is a brief description of what I did-
  • Replaced all fuel lines
  • Installed new German clamps on the fuel lines
  • Cleaned the injectors
  • Found good core VW heads and had them rebuilt with new valves
  • All new German valve adjuster screws
  • I cc'ed the heads
  • Replaced the bad piston
  • Replaced damaged rocker arm and push rod
  • Cleaned all pistons (spotless) including landing rings
  • Balanced the pistons within 1/10 of a gram of each other
  • Honed the cylinders
  • Measured deck height
  • Set compression ratio to 8.0 with the proper base gasket/shim
  • Replaced the thermostat
  • Replaced thermostat pulley
  • New NOS Leisteritz muffler and tailpipe
  • Replaced muffler heat shield
  • Removed the catalytic converter
  • New motor mounts
  • Installed all new exhaust gaskets, using new bolts and copper nuts
  • Spent an insane amount of time cleaning and painting everything
  • All new tune up components
  • Cleaned up any bad electrical connections

I am sure there is more that I have forgotten to list.  This work took about 10 weeks, but the result is a smooth, strong engine.

After about 50 miles I will recheck valve clearances, and after something like 300 miles I'll change out the oil and filter.

Some photos and a video of the result are below.
Lucy is now On The Road Again!
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  • Home
  • Exterior
  • Interior
  • Engine & Trans
  • Tool/Travel Kits
  • Documents
  • Accessories
  • Underside, Steering & Brakes
  • Events
  • Misc.
    • Misc. Stuff
    • Electrical Diagram
    • In The End
    • Typ 64
    • Willhoit-Leno 356
    • Million Mile 356
    • N. C. Museum of Art
  • Vintage Photos
  • Original vs Repro
    • Original vs Repro
    • Original Porsche Crests
    • Original Interior Door Handles
    • Original Ashtray
    • Original Durant Mirror
    • Original 356 C Spare Tire Straps
    • Original 356 C Bumper Guards
    • Original Reverse Light
    • Generator/Fan Belts
  • Our Air-Cooled Journey
  • Contact Us
  • TRANS OCEAN MOTORS
  • Restoration Work- Blog
  • Classifieds
  • Made By Hand