The Project The Sage on 07 May 2009
No good deed goes unpunished…
It’s one of those horror story situations…
In corner A we have Mike, who has two 79 Westy buses, one with a good 2.0 liter engine, but a so so body, the other; a mint condition Champagne edition, with a crappy 1.8 liter engine with no tin or compression.
The task seems straight forward: Swap the engines.
The Deal: Pull both engines, upgrade the heads, replace the cylinders, rings and pistons, replace the shocks, replace the accelerator cable.
Compensation: The other 79 Westy with a 1.8 liter engine in it, signed title and keys.
The Cast: Mike; The nice guy with a desire to get his bus on the road. Nameless X; The buddy who has been wanting a bus for a while now, and has “skills”. Sage; The idealistic jump before you look champion from 2005 - 2008 consecutively.
The stage: We have excellent working conditions, an old mechanic’s shop with tools lighting and a concrete floor.
Thursday May 7, 2009 10:30am X and I arrive to look at the tasks. Seems straight forward. I have the tremendously valuable Engine Removal in 20 Steps by Ratwell.com ready to go. We review the steps and start in on the OK bus. The 20 steps in engine removal mostly entails the wires, and fuel lines and FI systems. The three last steps include the 4 engine to transmission bolts, and the rear bracket.
We are slow to start; finding the right tools, developing a rhythm and breaking the rusty nuts and bolts takes time. The rear cradle and engine support bar take forever. This is the point that swearing begins.
2:00pm Engine one is free and on a dolly. It is fairly rough looking, but it is free from the body.
As we start on the second engine; the one in the really nice bus, we take care to make sure we are gentle and use plenty of towels so nothing gets scratched. We determine that we do not have enough clamps to close off the gas lines. X is tasked to acquire some from the local Menards. I go to work with steps 1 - 15 of the Ratwell guide. X returns as we approach the bolt removal steps. The only items left on the task sheet are the removal and clamping of the fuel lines, and the disconnect of the throttle linkage (which is vastly different from the manual version of the late bay bus).
I work on the driver side, since we are replacing all the fuel lines, I use the clamp and cut method of fuel line separation. My work is done, X is under the the bus taking forever to remove the fuel return line. More swearing, but to use such language in such a simple removal exercise is really unnecessary.
I am taking the moment in the entry to discuss safety. Since beginning this project, I have dented my car twice, had my trailer detach once, and had some minor bumps and bruises. No serious injuries have occurred. I wear safety glasses, face shield, work gloves and other things that keep me safe. Another safety tool I have is something that stops me mere moments before something really stupid happens. Call it one of the little voices in my head. I have never been to the ER thanks to a Volkswagen project.
At this moment, as I am napping, sorting tools and generally getting impatient with X’s inability to pull a rubber hose off a metal tube, when all of a sudden he dashes out from under the bus, starts swearing more violently, and rips off his safety glasses.
“Fuck” he summarizes “I have gas in my ear”
Immediately, he runs out of the building, and I quickly follow him. My first thought was man, he really knows how to yell. My second thought was to flush the gas out of his ear. We start with a series of flushes from my drink bottle, but this doesn’t seem to have too much effect; so much for Artesian Spring water. My third thought was that it was time to get him to the ER.
We get in his truck and race the 7 miles into Traverse City, all the while he is banging his leg up and down like the drummer in an eighties hair band. I can tell he has real pain, he has his head tilted sideways. Being thoughtful, I start yelling out landmarks along the way. If it doesn’t provide a sense of hope, it should provide a mild enough annoyance that he is distracted from his flaming ear.
Suddenly he picks up his phone and starts dialing. Now I know I enjoy a meager social life, if I wanted to call someone at 3 on a Wednesday, there isn’t anyone I would know to call. If I had gas in my ear making social calls wouldn’t be on the list of things to be doing.
“Doctor X please” pauses, while his foot keeps thumping the floor pan. “Hey, it’s X, I just got gas in my ear, and I am on the way to the ER” another pause “I’ll be there shortly”. This guy must visit the ER often. He has memorized the staff and phone numbers…
Traffic is heavy, but with a little weaving we arrive in an efficient manor. We get him checked in, I look like a complete freak, with grease and dirt just about everywhere. I help him with the little forms, and he is told to take a seat.
It then occurs to me that he hadn’t taken the time, while the gas was sizzling in his ear, to actually clamp the gas line. I immediately leave the hospital and head back to the work space, fully expecting to see large clouds of black smoke billowing into the sky from the general direction. There isn’t, and when I get back a slow but steady stream of gas is creating a pool on the floor in the shop. In the center of the vapor lake is the shop light.
Step 1: Unplug
Step 2: Remove light from gas
Step 3: Move the bus
Step 4: Stop the leak
Step 5: Soak up the gas
When the immediacy of the situation comes to a close, I think to call Mrs. Sage to discuss the goings on. She of course already knows, and proceeds to lecture me about things I didn’t do.
X calls me about 4 O’clock. He wants to go back to work on the buses. I tell him that one visit to the ER per day is my limit, and that I will call back later. The doctor tells him to not smoke for a few days. Sage advice.
(More on the project later…)
This is the story about chasing a dream. Not some perfect dream, more like a short sighted dream. In June of 1993 I bought my first VW Bus. In January 2006 I bought my second. One year later, I have owned over 20 VW’s and I am wondering what went wrong.
A Barndoor bus is is the original design. Buses are broken down in this way: 1950- Mid 1955 are “Barndoor”


We head to Ted’s house. It’s a really nice place, in a quiet part of town. Ed and I are staying at a hotel, while the rest are shacking in various locations around the house (lord help his wife).
This means one thing to them Cracker Barrel . Here is a chain that makes the portly feel right at home. All those filler foods I avoided at the buffet? That’s all they serve here. Pigs are contorted in so many ways in this place, I don’t think they can be called meat any longer. We wander through the gift shop of crap (who puts a gift shop in a comfort food restaurant?) to our table. Any time a career waitress sees 5 nit wits like us be seated in her section, experience tells her a couple of things; this isn’t a simple turn, and I will probably not enjoy myself. She proceeds with delivering a marginal experience. The disappointment comes when I go to order my staple at this place, and they are out of it. How can a restaurant with this much hick in it be out of oatmeal?! I get french toast, without fruit, or whipped cream or cheese or bacon or other unnecessary things. We mail a signed menu to our friend Jon as always, this time certified mail.
I enjoy taking advantage of hospitality as much as the next guy, but Ted has been recently sick. Unbeknownounced to him, the rest of us planned to help him get his project back on track. He needed his engine pulled, and some light body work completed. The one thing everyone there knows is VW’s. We push the bug out of the garage. The engine is out in 22 minutes and stripped down in another 15. The fenders, nerf bars and other things that need addressing come out in a matter of 45 minutes.
reason for this endeavor least we forget). Ed and I leave at 11pm with Russ asleep in a chair, Dave already in bed, and Rob playing with his laptop.
at The Samba. This car is once again a mess, and once again pretty rare. I don’t know why we have so many first model year cars up here, but we do.
On New Year’s eve we had a family meeting and decided to move forward. Arrangements were made, and Lynda and Martha went down to get her January 3rd.
On December 8th I had to make the decision to have Polar put to sleep. He was our family’s six year old Bernese Mountain Dog, and my traveling companion. I don’t normally talk about non VW stuff here, but he was a part of this world of mine.
Polar with with us almost exactly 6 years, he was my dog, going to work with me most days and traveling to 21 states and Canada. We were preparing to do the Shore to Shore trail next summer; Empire to Oscoda. We had worked up to 20 miles a day. We hiked in Colorado to the continental divide, and most of the Sleeping Bear Dunes. He was the best trail dog I have ever had, staying out 20 feet and coming back to “check in” every so often.
Sunday Night: Rain and snow showers. Some thunder is also possible. Low around 35. Breezy, with a west wind between 20 and 25 mph, with gusts as high as 35 mph. Chance of precipitation is 80%. Little or no snow accumulation expected.
Monday: Rain and snow showers likely. Cloudy, with a high near 40. Breezy, with a west wind between 20 and 25 mph, with gusts as high as 35 mph. Chance of precipitation is 70%.
Monday Night: Rain and snow showers likely, becoming all snow after 2am. Cloudy, with a low around 32. Northwest wind between 10 and 15 mph, with gusts as high as 25 mph. Chance of precipitation is 70%.
Tuesday: A chance of snow showers, mixing with rain after 2pm. Mostly cloudy, with a high near 39. Chance of precipitation is 50%.
Tuesday Night: A chance of snow showers. Mostly cloudy, with a low around 30. Chance of precipitation is 30%.
Wednesday: A chance of rain and snow showers. Mostly cloudy, with a high near 45.

Glenn is a pretty neat guy. He knows quite a bit about performance engines, and owns a 1974 bug he has had since new. After Martha fell asleep, he and I sat up and talked about things for a while.
My favorite car was this 1958 Karman Ghia convertible. This was owned by a guy named Rob whom I had a chance to speak with. He purchased it restored, but he has a vast knowledge of the older VW”s (pre 1960). It took about a dozen photos, in hopes it might inspire me to do something about my Ghia’s. I hasn’t yet.