Find TDC when TDC is missing

A diesel and specifically a TDI is super sensitive to timing settings. To make a good timing setting you must find the TDC. Sometimes you can't or have the tools needed.

I've done it like this several times when the belt has been of with good results.  Everything is referenced with the first cylinder. Remove the glow plug or the even better the injector for the first cylinder. Use a long metal rod (welding rod is perfect) and let it rest on top of the piston. Turn the engine slowly until you reach the point where the rod is standing still and starts moving down again. Vision is good but with a finger resting on the rod you'll be amazed how accurate you can be. Turn the engine back and forth a few times to find the two points where the rod stops moving and the point where you have the smallest movement noticeable again. You have now found the two points that are the entrance and exit points for the crest of the TDC. This means, right in between these two points you have TDC. If you can you should now mark it up with a drill mark or similar on the flywheel.

Mirror End Cap install instructions.

The end cap printed in Frosted Detail has a very nice detailed finish. The surface is a little bit matte and it will catch dirt quite easily. I recommend to add a thin layer of clear coat on the outside to make it easier to clean and to be dirt repellent. No need to sand the surface, the surface is perfect as it is for coating. A normal rattle can spray will do the work.

Also, the end cap can be tinted (colour added to clear coat) to match the vanagon better.

Buy an M4 stop screw, 6 - 8 mm in length. Turn it into the hole, but be careful as the threads are already there and make sure that the screw is going straight in.

Turn the screw all the way in.
The Allen Key (Hex) size is 2 mm, a Torx size T8 works too.

Mount the cap. The end towards the door panel goes first then push the cap up.

Turn the screw out a few turns (anti clockwise) to lock its position.
Done!

And finally just to give a feeling of its nature.
This is how it looks when illuminated with one LED, the built in flash light of a smart phone.

Mirror side LED

So, this project got stuck and I was feeling disturbed that I didn't finish it up. Long time ago. Then a guy sent me a link to Shapeways that 3D-print objects on demand. I've been ignoring the 3D-printing as the tolerances have been too bad and the end result very coarse. But Shapeways are using laser sintering for printing, which means that an object is sliced into very thin layers and each layer is then laser hardened into the previous. The tolerances are close to 0.1 mm. Of course it is not as good as injection moulding, it is good enough though. Actually I am now 3D-printing threads directly into the object. And as I see it; better that people can get the mirror end cap in one way than not at all.

So, the idea is to reproduce the Vanagon Multivan mirror end cap in a transparent plastic. With a transparent end cap it can be filled up with electronics, for example LED's that are connected to the blinker relay. The Vanagon side visibility is terrible and the position and blinker lights are low. This is an improvement for road safety. I've also made them in solid plastic for people who needs a replacement or want to paint their van in a new colour without electronics.
Both options are heat resistant to 80°C / 176°F.

First batch of test prints are coming this way. As soon as I have tested them, just order a pair yourself!

You can find them at the Shapeways page here.

A vanagon is pretty useful

I made a balcony fence to a guy and suspected that I needed a trailer to transport it. But nah, it did fit in the trunk. :)

The PVC hose test

PVC hose vs brake fluid test. This hose has been hanging since 2011 on the workshop wall to test if a standard air hose can take the brake fluid as a replacement hose in the Vanagon clutch system. As you can see, it is still dry and fresh.
The hose going to the slave cylinder can't be bought any longer, but now you know where you can find one that survives the fluid.

ALH TDI arrived!

Let the fun begin. It is time to start coding some ECU stuff.. :)

Steering wheel upgrade pt 2

The T4 wheel has the same size as the Multivan servo wheel. But the design of it makes the driving much nicer for the arms and hands. Bolt on!
I give this simple upgrade 5 Vanagons out of 5!

Pilot upgrade

A friend went to a scrap yard and collected an early T4 steering wheel for my T3. Thanks Abdullah!
everyone that did this update claims that the steering and comfort is much better. I think it will be great as the servo is super light even with the large SUV tires. To be continued...

Fwd: Golf tdi motor

Time for an upgrade! :)
The m-TDI is running great, but I have no idea how many miles it has. I've always wanted a newer engine for several reasons (emissions, VNT turbo, more power without tuning etc) and now I found an ALH in decent condition with a serviced turbo and a newly replace vacuum system. And best of all, this engine has the oil filter replaced from the top! 
It means that if I make a skid plate, which also lowers noise, I don't have to remove it to replace the filter.

Need to take care if a heat leak...

The bus is running weekly and it passed another MOT with no comments. The inspector said this was a joy to inspect.
But I've found that I need to take care of leak of the worst kind - the defroster package is leaking when the heater is turned to hot. Which means I have to disassemble the entire dashboard, steering column and the heater core... sigh.
Time to clean up the garage and make it happen. No treat no surrender.