Milly the 1979 Westfalia Berlin Deluxe Bay Window Camper Van

[chrisradioman]

The old brake flexies are shot & badly perished, Tudor thinks they are the originals.
The drums & discs are also original but thankfully very good condition.
The front pads were very thin & wouldn't have lasted much longer.
The rear shoes were very thin & the rivets are nearly through. I did say rivets so they are probably the originals too.
The rear adjusters were seized solid but Tudor has freed these off now.
The rear cylinders are good but as I have NOS ones, Tudor is fitting them.
The cylinders are from Autocavern so they are proper old.

[chrisradioman]

Tudor made up some cupernickel pipes to replace the ones picked up as an advisory on the MOT.

[chrisradioman]

The new brake shoes didn't have the handbrake leaver on them so Tudor drilled out the old rivets, machined 2 new rivets on the lathe, & peened the ends over to replicate the originals.


Back brakes all reassembled with copper grease & ready for the drums:-








You can see the old flexy:-



The new one here:-

[chrisradioman]

The other side:-




The new one:-




Adjusting the rear drums:-



Bleeding the brake's, flushed all the old fluid out & replaced with new:-



Filled up with new fluid, this will be changed again in 3 years:-

[chrisradioman]

Since the rebuild we've had an issue with the injector seals, Tudor & Mike have now resolved this by making their own. They spent all day today sorting the seals out & tweaking the settings, the van now runs sweet as a Swiss watch:-

[chrisradioman]

Finally Tudor replaced the oil & filter, Milly is now right until next winter:-


The clutch was OK & no adjustments were necessary, I thought so as it drives nice.

I had no real issues with the gear change but anyone else who drives it can't quite get the hang of it. Tudor told me the Empi gear change I have is rubbish so he & Mike made up a spaser adapter thing & now its much better.

[chrisradioman]

Revisiting my old list:-
1.) Replace the brake flexy's.Done
2.) Replace the solid brake lines from the flexy's to the calipers.Done
3.) Bleed the whole system so it has new fluid. Done
4.) Check the discs, pads & calipers, replace as necessary.Done
5.) Check the drums, shoes & & cylinders, replace as necessary.Done
6.) Check & adjust the handbrake cable.Done
7.) Change the engine oil & filter.Done
8.) Replace the fuel injector seals.Done
9.) Sort a sticky tappet I have when cold.Done
10.) Sort a small rattle I have when idling.Done
11.) Check & adjust tappets.Done
12.) Check & adjust the gear change.Done
13.) Check & adjust the clutch cable.Done
14.) Check the whole vehicle over & replace adjust or repair any defects.Done

[chrisradioman]

Tudor was impressed at the condition of the underside of Milly & has recommended an application of a product called Dinitrol:-
http://www.frost.co.uk/automotive-rust- ... litre.html

[chrisradioman]

Tudor & Mike made up some spacers for the Empi gear linkage because the ones that come with it are rubbish, this allowed them to set the gear linkage properly so now you have to pull the leaver to select reverse & the other gear movements are silky smooth.

[chrisradioman]

Tudor told me that my battery is shot its 4 years & 1 month old, it had a 4 year guarantee, DOH!
I'm going to get a new one, the one he recommended is:-

Bosch 12V Silver Car Battery HSB075, its the right size & fit for a bay & the best on the market.

http://www.alpha-batteries.co.uk/brands ... r-battery/

[chrisradioman]

Just picked up Milly from Tudors house & all I can say is WOW! it drives like a new van the gear change is silky smooth. I thought the brakes were good before but now they are lethal (in a good way) The van pulls up very fast. I didn't think they could be that good on a heavy van.
The engine is now very very smooth & she idles like a new car.
Tudor has recommended a new battery, I bought a new one 4 years & 1 month ago so I suppose its due a new one.

[chrisradioman]

T M Specialist Vehicle
Engine and Transmission Services
Fforest, West Wales
07721 466456

Work undertaken for Mr Chris Jones on VW T2 2000 Westfalia EAO 152T - November 2012

Remove all 4 wheels, strip out front and rear braking systems
Inspect and measure disks – all OK within spec
Un-seize n/s brake calliper piston, clean callipers, size and fit new pads
Fabricate link hoses in cupro nickel pipe
Fit stainless steel front flexi pipes and treat joints with comma wax
Fabricate fulcrum rivets for rear hand brake shoe arms
Clean back plates, change cylinders for new old stock
Check and measure drums for wear and ovality – all OK within spec, little wear
Remove and un-seize adjusters by heat, clean and copper grease
Assemble adjusters, rear shoes to back plates and fit drums
Adjust rear shoes to initial settings
Adjust and balance hand brake cables to give binding on 6 notches, locking on 8
Fit the 2 rear stainless flexi pipes, treat joints with wax
Pressure bleed the whole system introducing new fluid
Fit wheels, torque nuts correctly and adjust tyre pressures
Test run vehicle, return and re-adjust brakes

Change engine oil and filter using best 15/40 oil
Run engine and examine for air leaks
Strip out fuel injectors, manufacture seals to correct size
Carry out vacuum / pressure tests on primary and secondary air systems
Discover faulty deceleration valve, modify air transfer to correct
Check timing with strobe and adjust to 7.5 deg btc
Set fuel injection system on krypton gas analyser to give CO 1.5, HC 280
Test run vehicle and make final adjustments

Remove after market gear stick to rectify reverse selection problem
Fabricate spacer blocks to replace inferior spacer
Elongate mounting holes
Re-fit gear stick, set up and synchronise for correct selection of all gears and reverse gate








T Morgan

[chrisradioman]

Went through the recently removed old brake parts, the pads, the first three aren't 2 bad:-




This one must have been on the sticky piston:-


Look how old these are, can anyone remember Autocavan?


The new pads:-

[chrisradioman]

The old cylinders:-


The old shoes:-





You can see that the linings are starting to break up & the rivets areworn badly, I was lucky that it did not score the drums:-



The rear flexy's were very bad & it looks like I should have changed them a long time ago:-

[chrisradioman]

The original aircon pump & the one I've recently acquired:-


The condenser ready to be sent away:-


Milly back home safe & sound:-