Paying the Piper

Well, the opportunities for free diagnostics, et all, have ended. It is time to start making purchases.

Having pushed through many projects on a budget of 'pay as you go' and 'whatever it takes' and 'we're in too deep to stop now' I have decided that we're going to treat this project differently. I'm going to keep track of every blasted nickel on this project, and I'm going to factor in how much I have done cost avoidance, and keep the refurbishment of the vehicle separate from cost of putting the engine back in running order, that way those who wish to watch the costs mount for a refurb in process can do so, even if they have no need to pursue an engine rebuild.

In the blog format, its going to be a little interesting to see this information, since I will constantly have to link back to this page as time marches on. I'm going to try to reference what the source of the part was, that way I have a clear understanding when I'm done of how much had to be sourced 'used' instead of new.

Costs of General Refurbishment to Date (e.g. everything that isn't the engine itself.) 

General Components, Supplies and Services purchased to date: $686

Replacement BA6 Heater, Complete: $80 (skills@eurocarsplus, thesamba)

Center Sliding Windows from 78+ Riviera: $150 (Torrance, CA, thesamba)

Left Rear solid window glass: $10 (Maple Grove Bugout)
Replacement Fuel Tank: $30 (Maple Grove Bugout)
Wiper Motor, Linkage and assembly: $25 (All Aircooled Gathering)
2x  5x7 brown carpet for center section replacement: $36 (Big Lots)

Fuel Tank Sealer: $62 (POR15 PN: S7Q)

Muriatic Acid 1gal: $7 (Home Depot)
2x Shift Rod Boots ($11, WW)
Front Shift Rod Bushing ($5.50, WW)
Rear Shift Bushing ($4, WW)
2x Middle Shift Bushings ($8, WW)
Fuel Filler Neck ($19, BD)
Fuel Filler Lower Elbow (Dodge/Mercedes, $14)
Fuel Sending Unit ($39, BD)
Cab Shifter Boot ($6, BD)
20" Battery Ground Cable: $10 (Autozone PN: GT220B)
Positive Battery Terminal End 4AWG  $10 (Autozone)
Corroseal Rust Converting Primer 1qt: $23 (Home Depot SKU: 324826)
3x Catalyzing Primer ($15 Lowes)
10x Brake Cleaner ($40 Autozone)
Rear Hatch door ($120 Manny Parnossin)

Costs Avoided or Offset to Net Positive: +$398

Bosch Fuel Pump, refurbed, tested: +$250
Bosch Fuel Pressure Regulator, refurbed, tested: +$90
Return of Strut Compressor: +$58

Costs of Engine Restoration to Date:

Engine Components, Supplies and Services purchased: $721

Custom Fabricated PCV Hose: $32.50 (GeeBee Racing, thesamba)

Custom Fabricated Decel Hose: $45.50 (GeeBee Racing, thesamba)

Custom Fabricated S-Boot: $75 (GeeBee Racing, thesamba)

General Vacuum Hose $4 (Advance Autoparts)

General EVAP hose $4 (Advance Autoparts)
Watts Vinyl Hose 1/2"ID x 10ft, $3 (Evap Can to Air Cleaner Housing, Home Depot)

Fuel Filter $7 (BD)
Engine Degreaser: $8 (Autozone)

3x PB Blaster $12 (Lowes)
4x FI hose clamps: $3 (Autozone)

1 meter 3/8" J30R9 FI hose: $12 (Autozone)

1 meter 1/4" J30R9 FI hose: $12 (Autozone)
Replacement Points set: $8.50 (Autozone)
Intake Manifold Boots ($15, BD)

Throttle Body Gasket ($6, BD)
Ex Manifold Copper Gaskets 5 ($7.50, BD)
Used T2B Heat Exchangers ($265, Bob Hays)
VDO Fuel Press Gauge ($25, JEGS)
Gates Fuel Fill Hose ($25, OEHQ) Wasted. Wrong size. oops.
Gates 27336 3/8" Barricade Hose ($11, OEHQ)
2x Gates 27335 5/16" Barricade Hose ($20, OEHQ)
4x Sorenson Fuel Injectors ($114, Autozone)
Pushrod Tube Guard Tins ($10, Jason Creation)
All other conversion tin and heat valves ($80, Litchfield show)
New Durability upgraded AMC heads from Suburban Engine: $150
NOS Magnafluxed Crankshaft $100 (Clark, Thunder Bay)
NOS Connecting Rods $100 (Clark, Thunder Bay)
NOS Kolbenschmidt Main Bearings $50 (Clark, Thunder Bay)
Factory VWoC GE Type4 crankcase $285 (John Connolly, aircooled.net)

Components, Supplies and Services Planned but not yet purchased: $1007

Webcam 142 Camshaft, Lifters, Cam gear $332 (Alamo Motorsports)
029-198-009 Reinz Gasket Set $70 (Aircooled.Net)
AA 94mm Pistons & Cylinders $220 (Aircooled.Net)
022-109-451 Valve Adjusters $52 (European Motorworks)
029-105-245B Flywheel crank seal $11 (Bus Depot)
021-105-247A Rear crank seal $6 (Bus Depot)
039-105-701 Rod Bearings $40 (Wolfgang International)
021-198-541 Cam Bearings $26 (Wolfgang International)
071-251-053EK Ernst Right Exit Muffler and Kit $250 (Bus Depot)

Window Seals LR,RR,LM,RM: $130 (Bus Depot PN: 221845321A & 211845341)

M8x1.25x12mm Qty 25 (Bolt Depot)
M6x1.00x12mm Qty 12 (Bolt Depot)
M6x1.00x16mm Qty 12 (Bolt Depot)

For the sake of argument, I'm also including the anticipated costs around a Subaru engine conversion, just to see how we make out.

Components, Supplies and Services Budgeted: $3255

Donor Vehicle: 1996 Subaru with SOHC N/A EJ22 Engine, with harness: $1500

Radiator: $400

Custom Wiring Harness: $400

Reverse Manifold Adapter: $150

Thermostat Adapter: $80 (Tom Shiels)

Cooling Ancillaries (Expansion, Overflow, Fittings) $300

Cooling Pipe & Hose: $350

OBD Interface Board: $75 (Smallcar.com)