it moves, its loud, but it moves!

Progress, progress. With an appointment at Meineke to build out an exhaust system set for today, I had a little extra motivation. Knowing everything was "good" according to my trusted mechanic friend, Justin, I moved quickly and confidently. I'll hit the highlights today, though there will definitely be more tomorrow.

Battery
Last night, I stopped at Batteries Plus and bought a replacement battery. With the instant discount and the mail-in rebate, it'll cost around $65 for a Group 40 (or is it 48?) Rayovac battery. I hadn't heard of Rayovak batteries since the old "I dare you to knock this battery off my shoulder" advertising. Apparently, they're deep into automotive batteries now. Anyway, I called them yesterday morning, and verified they had one, I picked it up and installed it last night after the kids were fed. I fired up the engine, grabbed T and backed the bus out of his hiding place into the driveway. There was much rejoicing.

Test Drive
T hopped into the passenger seat, and we tried to take a little spin around the neighborhood. We noticed a few things. First, an un-mufflered diesel engine is still really bloddy loud even if there is a turbo absorbing some of the noise. Second, while the engine was cold, the bus shook like a mother. After about 30 seconds it settled down. The clutch made all kinds of noise, and finding the gears was a challenge. I think I have some shifter adjusting I need to do. Reverse is easy to find, but I can't find first, so there's something batty happening there. Regardless, we drove around our little circle and around the neighbors little circle (cul-de-sac's) and pulled into the driveway. Our little test was over, but it totally passed.

Belly Pan, Clutch Cable Tightening
Before I could drive it to the muffler shop, though I had a couple of things I needed to do. First, I had to put the kids to bed, feed the animals, etc. Next, the belly pan that lives under the pedals needed to be re-installed. This keeps the weather from getting in there, which is especially important with the placement of the brake switch and the accelerator pedal switch. With the wet weather we've been having, we wouldn't want a puddle-splash to fritz the switches. I couldn't find the original bolts, but I found a handful of stainless 10mm bolts that fit. Last, the clutch cable needed adjusting. Now, the cable itself was relatively new before the project started, so it probably isn't fully warn-in. The clutch and pressure plate are brand new, so they will take some seasoning too. I expect to be performing some level of cable adjustment for the next few months accordingly. It had gotten to be about 9:30, so I called it good.

Drive to Meineke
My appointment was at 7:30, T needed to leave for school at 7 and C needed to leave for school at 8:45 (with a parent wake-up at 8). I am the only adult in the house, and I hadn't a ride home from the muffler shop. So, I woke before 6, with a funny plan for getting everything to align. First, I grabbed one of the kid's bikes and tossed it into the bus. I like bus-traveling with a bike anyway - its like a lifeboat. In case of trouble, you can pedal to a parts store from a roadside breakdown much faster and farther than on foot. Anyway, I pulled out of the driveway, and drove to the shop, using 2nd and 3rd gears all the way. Without the benefit of a tachometer, and not being familiar with the sound of an un-mufflered diesel engine, it wasn't easy guestimating the shift points. I relied on some common sense, though, figuring my shifts should come earlier than in the old pancake engine, and knowing that the accelerator only went to 78% meant I couldn't really get the RPM's into redline.
I arrived at Meineke as the defroster was starting to produce some warmth. I topped off the brake fluid (remember, I had it open to change the rubber lines earlier), pulled the bike out and rode home. I arrived home by 6:35, so I had time to prep for the day. T ended up staying home from school sick with that phflemmy coff thing that's gonig around, but I dashed back to the muffler shop to hand off the keys and talk about the project with the manager. "I want it quiet," I said. He accepted the keys nad I drove home to get C up for school. Again, I was ahead of schedule, and could enjoy some coffee before wrestling him out of bed. He got ready, ate and split for school (taking the lunch I made for him ) and I hit the road for work. I've spoken to Meineke from work, and the exhaust is done, with a lifetime warranty. Sweet. I'll drive it home, and post an update in the next couple of days about how it ran, sounded, etc.

It is hard to believe I'm actually at this point. There have been a couple of wrenchers without whom this would not have been possible. Hal and Justin, your assistance has been immeasurable and so, so greatly appreciated. I want both of you to sign the partition behind the passenger seat that's exposed to the main open area so your names will forever be connected with what we've done. There is time tomorrow to talk about what the next steps are, etc. For today, we smile. And nod. And bask in the gravity of the achievement we accomplished. Today, we have a 1972 VW camperbus getting pushed down the road by a 1998 NewBeetle 1.9 liter TDI engine.

pictures:
top - Justin fooling with the low-pressure return lines (we replaced them on Sunday)
middle - Hap's parking spot for nearly 2 years, now vacant (rain)
bottom - in the driveway, ready to go get an exhaust (rain)