Wednesday, July 16, 2014

One!

I came wobbling back home from my first Monday back at work since vacation. I say 'first Monday' and not 'first day' because I was corporeally present during the previous Thursday and Friday, but I was not present mentally. And the week coming up isn't shaping up too well, either.

I figured I'd get back from vacation on Thursday, bounce through catch-up stuff at work, come home and start applying all of the pent-up Bus-buildin' & fabricatin' enthusiasm that had been building while I was on vacation. (Clarification: My employer considers this vacation, since I book time against it, don't show up and get paid anyway. I do not personally consider it vacation because I am an introvert and this trip was to share one house in San Diego with most all of my wife's relations living in California. (15 people: some elderly, others senior, middle age, young parents, children and toddlers) for a week straight, plus assorted dinner guests occasionally raising the population to 21 for meals under one roof for six days. All lovely people, but we don't really go anywhere, we just sit around sweating (no AC) with occasional relief dips in the pool.

Nuts. That wasn't vacation. That's the relational equivalent of Chinese Water Torture. There isn't even anywhere to hide to read a book. The closing weekend, my wife and I were scheduled to decamp with my kids (still not a vacation if I have to ride herd on them) to Los Angles/Thousand Oaks with her brother and his family, who are all introverts, thank God. The relentlessly close quarters finally got to my son who had a grand-mal freakout which disqualified him from going, so my wife and I did the sensible thing when two parents have two children: each take one kid and go to opposite corners. I went to LA with my daughter and my wife stayed in San Diego.

Don't get me wrong...I love my daughter, despite the congenital defect of being an extrovert and a delusional (even for a 7 year old) narcissist. I love my brother-in-law, his wonderful wife, and my delightful nephew. But this still isn't vacation in the 'I get to do what I'd like to do' sort of way. Since every single vintage VW shop in the state (most of which are in LA) was closed for the long Federal Holiday weekend, there wasn't any place I could go that fed my vintage vehicle habit; even the perpetual car shows that seem to run from March to November in California were all shut down for the time I was in state. In lieu of being able to move my much delayed project forward, I decided to push sight-seeing for my daughter, who fancies herself an adventurer. So I gave her some adventure. (Cue fright music here.)

We drove South on Rt. 23 over the Santa Monica Mountains, what is considered to be one of the more notoriously dangerous roads in the state, as its mere 12 miles is repleat with wicked twists and mostly unguarded drop-offs into deep canyons while climbing and weaving up and up to a height of 2200ft. With foothills aplenty and near the ridgeline, you can see clearly to the Tehachapi range about 50 miles North-NorthEast, or 180° to the South and see the Pacific Ocean stretching out to the horizon.

Absolutely...blew...her...mind. Her biggest sense of scale previously has been driving the Walt Whitman Bridge over the Delaware River into Philadelphia. Mind officially blown.

Of course, that only used up about 90 minutes. So we continued down the mountain to the Pacific Coast Highway, parked by the side of the road, slipped on swimsuits, and went in the Pacific. At a surf beach. Bad idea. Bashed against rocks, my prescription sunglasses are swimming with the fishes, and I just about lost her (and she, me) to the ferocious undertow. Nobody said "Adventure" was safe.

So for ten days of declared 'vacation' I got one day off my leash, but with the proviso that whatever I do, it has to be safe enough, interesting enough, and mundane enough to justify taking my easily bored seven year old along.

When we returned home, I was chomping at the bit to 'do the next thing.' But things were broken, or that needed fixing, and nobody feels like cooking, and could I PLEASE clean up some of the jetsam in the bedroom. In a foul mood, I slogged through the piles in the bedroom and found the long ago ordered oil separator plate (and the weirdy-special 5.5mm broached button head bolts from Subaru) all of which replace the stock plastic (PLASTIC!?!) plate which is prone to leak like a wicker basket. Having lost the evening cleaning, I set the parts aside for installation, as the one thing I have learned in spades is to never go out to do delicate work when you are tired, angry, and stressed out. That is a recipe for broken pieces, ruined tools, and psychological meltdown. It can wait ONE night.

Except it was the same drill last night. Seeing that I was starting to look a little crazed, my beloved told me I was off my leash for the rest of the night and I scooped up the parts and headed for the garage before she changed her mind.

The oil separator plate replacement is about as idiot simple as they come. 6 screws & plate removed and tossed, clean the mating surface of old sealant, then Permatex Ultra Gray for the new seal, then apply 5 bolts randomly and one 'special' where the arrow points. Torque to 5ft/lbs.

I cleaned that mating surface until it was a narrow, curvy mirror letting all of my pent-up OCD out on it because the spot is a notorious leak point which cannot be accessed in situ, so the plate must be installed before I can transfer the engine to the hoist or add the flywheel or anything else. In project management speak, this was a 'blocking' procedure that prevented any other move to be made.

Having buttoned everything up, I marched back into the house and announced "ONE!"

"Sorry?" My wife looked up from the game on her phone she was noodling with while not attending to a baseball game on the TV. Both are there for her distraction, the same reason that I work on old cars.

"ONE thing is done. After weeks of immobility, I just got ONE LOUSY THING done."

One. Yet, it was the next one upon which all others waited. So in the totality of the project, it is a barely a pimple. But in this moment, straining at the leash before beginning major work to install the engine, it was the next thing, even if it was the only thing I've been able to shift in a month. Between nothing and something...I'll take one.

Monday, July 14, 2014

The Time Draweth Nigh

I went to a lovely show this past weekend, having just gotten back from vacation. The Deutsche Classic is one of the premiere 'all-emblem' shows on the East Coast, offering anyone with any vehicle from Germany to get together and see what else is going on with other vintage cars from the same era and region. It's fascinating to see how many parts are shared between Mercedes, BMW, VW, Porsche, etc. It also tends to pour cold water on the 'my marque is best' fatheads who believe that if it isn't a Benz (or VW, or Porsche,) it isn't anything. It lets you see other people having equal passion for their hobby, too.

One of the nice parts for me was to see at least two VWs (Vanagon's, I'll grant you) who had experienced engine conversions, one to a Ford Zetec (conversion by Bostig) and one to a Subaru (using SmallCar components.) The Subaru has already had (no joke, though my jaw fell open when I heard it) 140,000 miles on the road pushing the Vanagon around. The owner bloody loves it, though he is dis-satisfied with the quality of the parts from SmallCar. Still, it was nice to see a worked example even if it isn't my model with my additional challenges.

While toodling around, I met Jeff Hickens, one of those 'pillars of the community' who gives freely and has a good time doing it. He donated his old windshield to my Bus project to help get me on the road when he wanted new glass for his 1979 restored beauty, but he saved the old one when it came out and donated it to me. So nice. He was presiding over a stack of literature for the forthcoming All Aircooled Gathering in Flanders, NJ late in September. This is a great bash, and I was planning to make it, because they've got a great swap meet and every year they feature a specific model vintage VW to help encourage preservationists to bring 'their precious' out to share.

Oh dear heavens. This year the feature is the late model T2B Bay Window Bus. In other words, MY model.

10 weeks. 10 ruttin' weeks until the big hooha. If I poured all of the time, effort, money by the metric butt-load necessary into this, could I have it ready to make the 90 minute trip? Just douse myself in gasoline, set myself alight and work like a nutter until I burned down to a small pile of ash.... achievable?

No. Not because I don't have the will, but because I have neither the buffers of cash or time, at least not all at once. This a home shop fabrication project: The dance steps look like this 'one step forward, twelve steps back, twenty steps forward, eight steps back' and that's when not interrupted by family crises, illnesses,  frighteningly astronomical doctor's visits, relationship stressors, employment boondoggles, failing appliances and other quotidian chores. Having performed a regular some-assembly-required installation of Commercial Off the Shelf (COTS) parts the way the Big Green Book (Bentley Factory Manual) says to, I'll confess that fab and engineering solutions are a exponentially greater challenge than just assembly. 2014 has not been kind to my family, with fisgigging pops and crackles of radically unanticipated setbacks, and that usually means I come home from work, not so much to relax or retire or even have relationships with my family, but to ride in to the rescue and fix the next thing (or person) that has fallen off the Christmas tree. My wife succinctly (and without humor) refers to this as "Waiting for the other shoe to explode."

So even if I were able to integrate and assemble all of the bits and bobs that I already have at hand, then add everything else I know I need which I haven't sourced yet (fan housings, fans, dual circuit fan power control, preformed coolant hoses, expansion tank, exhaust system, air intake piping, air cleaner solution...) Even if I could make all of that happen, there's still a big, big list of items that are open questions that I have yet to explore their functionality:

Do the brakes even work? Master Cylinder? Calipers? Slave cylinders? Brake Hoses? If I get this thing going, am I going to be able to stop it, or am I going to wind up in the creek at the end of the block? If I turn the steering, will the tie rods move, or just take my suggestion to turn 'under advisement?' Turn indicators? How about that shifter? Or am I going to lose two shocks right off the back after the first pot hole?

This is the vehicle that has been in the worst condition that I've ever purchased (from a neglect standpoint) and it means that even the most mundane element must be validated, including components that are long term consumables (battery, tires, brakes, fluids, shocks, suspension components) to find out if they are even in serviceable order. Tires, batteries, brake fluid are all on 'replace regardless' list. That will be about $500 just there. Brakes? if I do everything from the spindles out (bearings, backing plates, drums, shoes, discs, calipers and dear God please don't let the brake vacuum canister be bad!) that will be another $400 minimum. Essentially...I'm having to plan to build the Bus all over again and hoping that statistics (and blind Providence) will mean that I won't have to replace EVERYTHING.

So full speed ahead on the really important stuff: the work that has to be done before the snow comes. (Do I think this far in advance in August? Hell, yes!) The money comes, the money goes, so I have to grind forward whenever the bucks bob to the surface. It means a fits-and-starts relationship with the project, but the only way to finish is to keep doing it.

Yay, me.

As an example, here's the breakdown of the anticipated "if it all goes wrong" cost of doing the brakes, bumper to bump, every component JUST of the brake system. That will be $1099, thank you. Gawgk!

Rear Wheel Bearing & Seal Kit (#211501287K)  Unit Price $39.95 $79.90
Brake Drum (#211609615)  Unit Price $55.87 $111.74
Rear Wheel Cylinder (#211611047F)  Unit Price $14.95 $29.90
Front Brake Pads (#D195S)  Unit Price $24.95 $24.95
Rear Brake Shoes (#421)  Unit Price $33.95 $33.95
Front Brake Backing Plate (#211405593)  Unit Price $24.95 $24.95
Front Brake Backing Plate (#211405594)  Unit Price $24.95 $24.95
Brake Hardware Kit (#17178R)  Unit Price $12.95 $12.95
Brake Shoe Adjuster Nut (#113609205A)  Unit Price $5.86 $11.72
Bearing (#211405625)  Unit Price $8.65 $17.30
Front Wheel Bearing (#211405645D)  Unit Price $6.86 $13.72
Brake Backing Plates (#211609425PR)  Unit Price $79.95 $79.95
Brake Master Cylinder (#211611021AA)  Unit Price $199.95 $199.95
Brake Hose (#281611775BMY)  Unit Price $12.77 $25.54
Brake Hose (#211611775BMY)  Unit Price $13.16 $26.32
Front Brake Caliper (#251615108X)  Unit Price $63.99 $63.99 Deposit: $27.00
Front Brake Caliper (#251615107X)  Unit Price $63.99 $63.99 Deposit: $27.00
Power Brake Booster (#211612103AX) Unit Price $199.95