Saturday, October 22, 2011

So, we actually started the project in late September, with the acquisition of a used Zetec engine.  I found an '03 with 13,000 miles within driving distance, and picked it up in the F150, carrying it home on a pile of used motorcycle tires.  Having both a truck and a bucket tractor (and a logging chain) made this easy.  The kit from Bostig - ten boxes via UPS - arrived shortly thereafter, and I hoped to begin in early October.  However, I encountered a series of schedule delays due to other events, and put off the start until we got through them.  I should add that the green puddle that started all this turned out not to be the head gaskets after all.  Our Volvo V70 wagon's power steering had a problem, Joan needed to travel (it's her van), and I decided to try to locate the leak and see if it might be a problem that leak-stop could fix.  I was reluctant to use such a product, fearing possible clogging of the radiator.  I ended up finding that a plastic pipe connecting to the cylinder bank had a minute crack in it.  After removing it and making numerous attempts to patch the crack, I located a replacement pipe (made of metal!), fashioned a gasket (the original gaskets are NLA) and installed it.  The engine leak was completely stopped.  However, I have no plans to delay the installation further, though being able to use the van over the last several weeks has been great for Joan.  The V70?  Another *&^!%$^% plastic part failure.  I have also just fixed the odometer in the Vanagon for the xxth time.  It has a PLASTIC drive gear that is a friction fit on a metal drive shaft.  What could go wrong? the designer thought.  Twenty years later ...

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