Monday, October 30, 2006

Illogical Pricing Fears

Everyone reacts the same when I tell them about the cracked intake manifold. They usually gasp and then say "That souds bad!"

Interestingly, I'm not stressed out about it much. I know exactly what's wrong, have ordered a $50 replacement manifold (exchanging that for the $70 manifold I initially ordered because the $50 manifold has removable heat risers making for easier installation) and will fix it.

I have a good idea the point of view people have when they react so strongly to the words "cracked manifold." I know most don't understand VW mechanical issues nearly as well as me, so hearing that something "cracked" and it caused the car to not run certainly sounds "bad." I'm also sure they assume such a thing will cost at least $1,000 to fix. They're also doing their best to empathize with me, assuming that I'm distressed about the situation.

I appreciate the heartfelt concern folks show when I tell them about it. But, it's a reminder to me of why I'm glad I've forced myself to do all repairs to this car myself. Had I not bothered to do that I'd be just as nervous as everyone assumes I should.

The approximate time I spent worrying about my car was five minutes. That's the time between when the car initially lost power on the highway and when I spotted the big crack in the manifold. Once the source of the problem was identified I knew exactly what was wrong, how to fix it and, within $30, how much it would cost. Much of fear and anxiety comes from the unknown.

On the opposite end, I get worried, anxious and nervous when I think about scheduling my next dentist's appointment. It's not so bad now because I've been to my current dentist's office twice before so I know where it is and what to expect. But, when I had to switch offices due changing insurance companies I called Reese for help because she deals with medical institutions all the time for work. Until I successfully made the switch from one dentist's office to the next I was anxious and nervous about it: too many unknowns.

I worry that I'll have trouble finding the new office, perhaps spend an extra five or ten minutes searching for it. I worry that the new dentist won't know my history as well as my previous and will mis-diagnose something. I worry that I'll have some really bad cavity that my previous dentist didn't see and I'll have to schedule another appointment. I'm not worried nearly as much about having my teeth drilled or novacane shots, I'm worried about scheduling.

So, from that experience, I understand why people react the way they do when I say the words "cracked manifold." I also understand I can't stop them worrying for me any easier than I can stop worrying about scheduling my next dentist appointment.

Nobody fears the known nearly as much as the unknown. I do have some apprehention about fixing the Ghia, but they're really minor: I may need to put Liquid Wrench on the generator pulley nut to break it free, I may have to get a new nut and bolt for my hacked-together distributor clamp or I may need to locate better hose clamps for new fuel lines. These are just little challenges I know I'll face but they make the experience enjoyable and I'm confident that in the end the Ghia will run at least as well as it used to; probably better.

Most people are just full of dread when their cars break down because most people don't know what's wrong with their broken cars nor how to fix them. There's a lot of anxiety also about how much money their mechanic is going to charge for the fix and then anxiety about finding the money to fix it. Of course, if given the choice between an expensive fix and a "cheap" fix that would work just as well, some people would still go for the expensive fix.

This particular phenominon was discussed in Robert Pirsig's Zen and the Art of Motorcycle Maintenance. He talks about his friend with a brand new BMW motorcycle that had a loose grip. All the grip needed was a shim and the friend wondered where they'd get such a part. The narrator holds up his beer can, indicating that once it's empty it's perfect shim stock.

His friend didn't take to that lightly, feeling insulted that someone would suggest fixing a fancy, expensive BMW motorcyle with a beer can. It's a logical fallacy: appeal to common practice. Just because the proper way to shim a loose hand grip is to use genuine BMW shims (if they even exist) doesn't mean that a cut up, steel (the book was written decades ago before aluminum cans) beer can won't work just as well.

I was reminded of this just a few days ago while visiting with relatives passing through town. They were staying with old friends and these old friends had neighbors over visiting as well. The husband of the neighbor couple had a '76 Alfa Romeo and once he saw my '72 Bus we got to talking vintage cars.

His Alfa has a fuel injection system that's stock and he talked about some day installing dual Webber carbs. A few times he'd chuckle as he talked about how expensive it is to do any fixes on his motor. Then he said a dual Webber carb setup would put him back at least $1,500. I wondered how that could be because you can get dual webber kits for VWs and old Porsches that run you no more than $1,000 and as cheap as $600. It's all the same carb, just needs a different manifold to mount them onto a different engine.

So, unless he's going to spend $500-$900 on small, aluminum pipes, I didn't understand from where the extra cost came. It was obvious he was falling prey to the appeal to common practice. His reaction to my question was to say that the prices in the catalogue were "probably over-inflated" but I'm guessing he's still going to overpay for parts that work just as well as their 1/2 priced cousins. It's an Alfa Romeo! You don't install $1000 carbs when you can find identical ones for $1,500! The car demands more expensive parts and won't run right unless it knows you've overpaid for everything.

But, in his defense I had only just met him. He very well could follow my advice and look online for a better deal. I'll side with my instincts, though, and guess that won't be the case.

Perhaps that's one thing that sets old VW owners apart from the rest? Only a few people on TheSamba's forums recommended I buy a new intake manifold. The rest just said "JB Weld will fix that. You don't need to buy a new part."

And, they're right. There is no hole in the intake manifold itself. It's completely separated from the heat risers, but all I really need to do is "glue" them back together with JB Weld. Heck, I probably could have fixed it on the fly with a pair of hose clamps! The current theory is that as the upper part of the manifold had broken completely loose when I pushed on the gas it just pulled the carburetor forward, tipping it and closing the float needle valve which robbed the carburetor of gas. If I'd just use hose clamps to hold the pipe on the heat riser I could probably have driven the car another 50,000 miles that way.

But, in this case I'm not practicing what I preach. I'm appealing to common practice and installing a new part. I can do that, can't I?

Saturday, October 28, 2006

Upper Engine Dismantled

Just had to snap some pictures of the upper part of my engine taken completely apart. Also a nice picture of my intake manifold cracked completely in two!


The naked engine bay. I've stuffed rags into
the cylinder head ports to keep debris out.


Pretty cool, huh?


The rest of the engine in pieces.

Thursday, October 26, 2006

Funny Thing Happened on the Way to Storage

Five blocks from home my intake manifold cracked:



Sounds and looks real bad! But, prices for new centermount manifolds like this one range from $40-$80 depending on new, used, rebuilt or what have you. Last winter I already took the topside of the engine apart so I know how to get in there, remove the manifold and install a new one. Guess I've got a new project!

The real loser here is my poor wife. She was looking forward to her usual garage parking spot that was supposed to be available today after I stored the Ghia at my friend Shad's unused, underground, heated parking space.

Two cool things about this:

1 - This is very likely a crack that formed over time and probably from the inside out, causing an ever worsening vacuum leak. That's why I could never set my idle quite right on the carb, if that's true! So, a new manifold should make the car run even better.

2 - I had to get towed home when the car wouldn't run and the quickest, most convenient way I could think of was to beg a huge favor for Jamie of Sunrise Cyclery just a block from my house. He towed my Ghia with his '66 VW Bus!


Here Jamie's hooking up the rope to his van


Making sure the knot is good and tight.

Sunday, October 22, 2006

Brakes!

I can't believe how well the brakes work on the bus now.

The brakes were the first major thing I knew needed to be fixed when I got the bus. I had to pump them two or three times to get good pressure in the brake lines plus the brake fluid reservoir wouldn't hold anything. Fluid would just leak out the master cylinder onto the floor.

I considered doing the work myself but with all the hydraulic lines and unfamiliar territory plus the safety issues of brakes I figured it was a job best left to a trusted professional. So, Friday Quality Coaches did a great job installing a new master cylinder, new rear slave cylinders (they came with the bus, stored under the back seat!) and new rear brakes.

That worked great, and I didn't need to pump the brakes anymore. But, my right leg was getting pretty tired pushing so hard to stop the thing. That made sense because it's twice as heavy as the Ghia and the brakes aren't much different. But, I did know it came with a brake booster and that was likely disconnected.

Sure enough, when I inspected the engine I found a big, fat vacuum tube coming out of the intake manifold plugged with a large bolt. I just didn't know where it was supposed to lead to.

This morning I started searching for a fuel leak issue and found the other end of the vacuum line to the brake booster just sitting on the engine. I invested about $10 in parts between a new vacuum line at Napa and a brass coupler from the plumbing department of Home Depot. Once it was hooked up in the Home Depot parking lot I started it up, fearing there was some leak in the vacuum line that would make the engine run like crap.

Good luck so far, the engine ran just fine. Then, I drove it out of my parking space, down the parking isle and tapped the brake.

I felt like I was going to fly through the windshield! I couldn't believe how well that booster worked.

Now I have to use my leg muscles to keep the weight of my leg from pushing too hard on the brake, otherwise I'm screeching to a halt!

I've been told by the Bus experts at TheSamba to keep an eye on it. There could be a reason the brake booster wasn't hooked up. If the vacuum canister/servo unit that is the brake booster has a leak that could show up over time and the booster would need a rebuild. Some place in Texas does rebuilds, apparently, for only $90, so that wouldn't be a big deal.

I'm betting (hoping) that the line was not so much disconnected as it was just not reconnected when the engine got rebuilt. I've heard of problems with the brake booster such as the vacuum line leaking and therefore causing the engine to not idle/run right. That may have been the case before the rebuild and one of the quick, hack job fixes to make the engine run better was to disconnect and plug the brake booster line.

Time will tell on this one. Until then, It's nice to know I can stop exactly when I want.

Sunday, October 15, 2006

A day for tinkering


I've been wanting a 12V power recepticle for my cell phone, so I picked one up at autozone for $2.50~ and installed it on the dash. There was an existing accessory hole at the spot between the radio and the Clock. I had to ream it out though to make the thing fit. Works great, now I just have to create a holder for the phone.

I also was having a problem with the right headlight. The high beam was out. So I bought a new headlight figuring that was the problem. Got the lamp, installed it and still no high beam. I was worried then that I did something to the switch when I dissasembled the steering column to pull out the ignition lock cylinder. But the left light high beam was working as well as the indicator light. The switch had to be working, maybe it was the relay? I finally decided to get some help and did a search of the Samba for clues. Duh..I forgot that each headlight both high and low beam are independently fused. Suggested repair twirl the fuse. So I twirled number 6 fuse and voila, now I have a high beam on the right headlamp. Need a new halogen headlight? I've got one.

The other repair I did saturday (which was my birthday, my gift to myself was a day of tinkering) was to fix the right side door. It didn't close tightly. I readjusted the latch so it would close tighter and now that annoying door rattle is gone. Hardest part - getting the bolt that holds the latch in place loose so I could adjust its position.

Last repair was to tighten the oil sensor on the engine. It was loose and as a result oil was leaking into the engine compartment. I'm slowly finding and fixing those pesky oil leaks. A Ghia doesn't have to leak!

Tuesday, October 10, 2006

Karmann gets a boyfriend

The only thing better than owning one 1972 VW ...


From the front


From the back


It even came with psychadelic magnets! (No way I'm driving around with those on.)

Sunday, October 08, 2006

Fall color drive to Galena




Last fall we drove to Mississippi Palisades park to see the fall colors. This year we wen with our neighbors Steve and Vicky to the park and then up to Galena for the annual country fair.
We stopped first at the park where you get a great view of the river from the top of the palisades.





Saturday was a beautiful day and the Ghia was really running smooth thanks to the valve adjustment and oil change. I figured I was getting 30 mpg. Performance that I had expected but hadn't been getting. Then of course It happened. When we went to leave, I couldn't get the key to turn in a lock. Finally after wiggling the wheel and inserting key in again and again, it turned and I was able to start the car. This has been happening recently on occasion and I've not paid a lot of attention to it.



We got to Galena and since the place was packed and we couldnt get to the park for a picnic, Steve and Vicky took us up on the bluff overlooking town and we laid out a sidewalk picnic. Great food and a wonderful view of the town.

Only problem, I couldn't get the key to turn again. *&^%*&& damn Ghia!

So we went for a walk and decided to locate some WD-40 to loosen up the lock.

Galena is full of great houses. What a beautiful place.

Well we found WD-40 and that worked with the lock. But when I got home and took out the key I couldn't turn it easily and obviously needed a more serious repair job. So when we got home I did some searching on the web and found several posts discussing stuck lock cylinders. The main recommendation is to remove the cylinder and clean it with WD-40 (or better yet liquid wrench) to get the old gunk out. This sounds easy but involves several tricky steps.

1. Remove the steering wheel:

  • To do this you have to first pry off the horn pad and disconnect the horn wire.

  • Next use a 27mm wrench to undo the nut

2. Remove the turn signal and wiper switch assembly:

You have to first unscrew a hex bolt that is accessible from the bottom of the steering column. This is not mentioned in any of the manuals but if you don't remove the bolt you can't get the switches out. The wires are all plug connected so you just pull them off and then you are ready to remove the switches. Four screws hold them in place.

Once your remove the four screws the switches will just pull out.

With the switches gone you can now remove the bracket that holds the lock cylinder in place. Just remove the two screws and expose the cylinder.

Now you can remove the cylinder assembly. Make sure the switch is unpluged at the back then insert the key and turn to the right to release the wheel lock and the whole thing will just pull out.

There is a hole in the cylinder housing that you stick a nail in that presses the release spring. The key has to be in the lock and turned to the left (off position). You can then just pull the cylinder out of the housing.

A lot of liquid wrench followed by WD-40 and the lock is as good as new. Key works smoothly and doesn't stick anymore!

I used some white silicon grease on the steering lock components and reassembled everything.

Everything worked great except the headlight dimmer switch. After removing the steering wheel again and on inspection I found that the switch was not making contact. A little piece of rubber and some glue and it now works just fine.

An awful lot of work but now I can start the car again.

I too am a mechanic

Well Chris finally convinced me to do my own maintenance. It took a while to get everything ready but Friday I finally was ready. Total cost for a tuneup $9.97. This was because I got a discount at foreign car parts for valve cover gaskets and a gasket set for the oil screen. The total cost for the gaskets - $1.97. I had to laugh when I handed the guy two dollars and said keep the change!

I was somehwhat surprised when I got under the car and found the right valve cover was a bolt on cover. It was caked with black gunk and it was obvious the oil leak that has been appearing on the floor of the garage was due to a leaky gasket. Some degreaser and elbow grease revealed the beauty pictured here:



The one on the right isn't nearly as pretty. I wouldn't mind finding another one some where so I have a matching set. I think sometime in the past the bail must have rusted and broken off. Anyway the valve adjustment was fairly easy with no major problems. Number 1 cylinder didn't need any adjustment. 2, 3, and 4 were all too tight and had to be adjusted. The oil change went smoothly and there are no leaks now!

Thanks Chris for making me do it!

Sunday, October 01, 2006

Fall Color Drive, 2006

Finally got the Ghia out among the fall colors. Didn't get to that last year but Reese and I spent a nice day in Sillwater, MN and along the St. Croix River Valley. Here are some pictures:


Here's a nice shot of Reese at this little Italian bisro in Stillwater where we had lunch. Only $20 for a really nice lunch.


Reese gets carsick if she does anything in a car like reading or operating a camera, so I had to snap a drivers-eye-view picture.


A nice picture of my old girl. Note that nobody's standing in front of it blocking the view.


Here's me blocking the view of a really nice car.


A panoramic I put together of the St. Croix River Valley.