Engine not in bus....

In brief, my measurements let me down again. First, my measurements for the vacuum pump and coolant flange were off. As a result, I spent the afternoon banging the engine/transaxle against the fuel tank. So, I pulled the fuel tank yesterday. Today, I set to installing the engine/transaxle again. This time, no matter how I tried, I was unable to get the transaxle mount points together. The intake and oil filler were banging against the ceiling of the engine compartment. So, what does this mean? I have to cut an access hole of some kind into that ceiling. I suspected this over a year ago, but after taking measurements over and over again, and determining it would fit, I moved on. Now, I need to get a sawzall or an angle grinder with a cutoff wheel and cut a hole in the ceiling.

Based on the measurements I took before, there should have been about an inch of space. That's what makes this so frustrating and confusing. To be fair, I've seen another TDI install in a splitty, and he put a hatch in. I guess this was inevitable. So, tomorrow, I'll be off to Harbor Freight for a cheap 4 1/2" angle grinder. Yes, I'll check craigslist first. The more important question, though, is how large a hole to cut? I have decided to cut a hole that will fit a type4 lid. I'll get a lid from the nice folks over at the DDB here in Portland at some point. I am approaching this from a "do what needs to be done to get the bus in the garage before Winter fully takes hold" perspective. I would rather move more predictably. I would rather have a firmer plan than react to problems, but that's where we are. I don't have a fuel tank solution. I don't know how big a hole I need, or how I'll fit a cover. I may have to "build a box" over the hole - some Vanagon conversions have to do that. It doesn't matter. For now, I'll be measuring and cutting a hole 2" smaller on all sides than the type4, thinking I can make it larger later, if I need to.

I'm taking all of these events as opportunities to learn something about working on the bleeding edge, and something about patience. I don't think of myself as a very patient person, but other people seem to think I am. I guess I just freak out about things on the inside. The goal hasn't moved: bus in garage asap. The limitations have been dropped, though, and that can be freeing.

I'll take pictures of the hole, and of the engine install, once its in place. I was able to see that nothing else would prevent the transaxle from mating. I take that as a great sign. Once the hole is cut, the engine/transaxle will mate, and I can roll the bus into the garage. I'll figure out a fuel tank and a hatch solution then. Thanks for reading, and I'll have more later.