I've got a race prepped Zetec (ZX/2 and Focus bits) that's about to go into a bus.

Race prepped meaning P&P heads, recent valve job, ZX/2 cams, FS header, and soon-to-have SCT tune. This engine was in a Lotus 7 replica used by a racing instructor and was rebuilt right before I got it.

Stay tuned!

sounds neat. needs pics though!

Photos needed!

subscribed!

Where are you going to put the radiator and cooling fan?

Where are you going to put the radiator and cooling fan?

Radiator with fans will go under the body, between the frame. I've seen guys try to cram them in the engine bay, relying on the side scoops, but I think under is better. The AC condenser core will go under there as well. Pics soon. I'll have a build site for it as well. This baby is a full Westy camper, but I'll drive it around for a little bit with nothing in it ;-)

And it's going to go through a full re-build on the body. I didn't say "restoration" because it's not going back to stock. Imagine a retro-modern apartment on wheels. Yeah, that's it.

Here's a pic of the engine with the new front end:
https://sites.google.com/site/78busbuild/home/DSC_0252.JPG

Other side of the engine with the header, CoP mockup, A/C compressor, and P/S delete:

https://sites.google.com/site/78busbuild/home/DSC_0253.JPG

And here she is right after getting her home. Yeah, there's a bit of work to do.

http://www.youtube.com/watch?v=TpzMvmmzwuM

The only potential disadvantage I see to under the body is the potential for road debris to damage it. Sounds like a cool build.

Now thats badass!

subscribed

Where did you get the P/S delete bracket and pulley from?

excellent. I came across a zetec vanagon once and wondered wtf. BUT I know why now and I bet it will do well.

Where did you get the P/S delete bracket and pulley from?

I got it from ScrapSteel and WeldSomeNuts2It. [cheers]

The pulley is a Ford 6-rib idler you can get for ~$8 new.

This is great. I love Westfalia's. Any idea what kind of power the Zetec is making?

Where did you get the P/S delete bracket and pulley from?

you can check out bostig.com if you are looking for a p/s delete setup.

they actually have entire kits to do zetec swaps into vanagons.

Now thats badass!

You have to forfeit a lot of torque and powerband flexibility to exceed the 200HP threshold with a N/A Zetec. That isn't a particularly good plan for pushing a heavier chassis even if you installed a 6spd. Today's base Dodge caravan has 280+HP 24V V6 with 6spd auto and gobs of torque...asian offerings are similar. They give a featherweight Zetec Focus a run for their money in a straight line, so add 450lbs and figure that one out. Badass doesn't come to mind because a soccer mom will outgun you. I guess I just don't understand the point of transplanting an alternative 4 cyl econobox motor into a VW bus. It's like putting a Cobalt motor in a Honda SUV. Perhaps this engine transplant kit is the only reasonable way to bring a VW microbus into the 20th century, I don't know. I would probably leave VW bus restoration to VW fanatics who endeavor to build concours garage queens with a correct German motor. [???:)]

You have to forfeit a lot of torque and powerband flexibility to exceed the 200HP threshold with a N/A Zetec. That isn't a particularly good plan for pushing a heavier chassis even if you installed a 6spd. Today's base Dodge caravan has 280+HP 24V V6 with 6spd auto and gobs of torque...asian offerings are similar. They give a featherweight Zetec Focus a run for their money in a straight line, so add 450lbs and figure that one out. Badass doesn't come to mind because a soccer mom will outgun you. I guess I just don't understand the point of transplanting an alternative 4 cyl econobox motor into a VW bus. It's like putting a Cobalt motor in a Honda SUV. Perhaps this engine transplant kit is the only reasonable way to bring a VW microbus into the 20th century, I don't know. I would probably leave VW bus restoration to VW fanatics who endeavor to build concours garage queens with a correct German motor. [???:)]

The point of VW buses isn't to be fast. Many would consider it difficult to merge in a stock VW bus. Consider that stock an air cooled bus probably makes as much as 65hp then a Zetec swap makes more sense.

The possible swaps for a VW bus generally include small engines. I've seen one with a Subaru engine (either out of a base Impreza or WRX, can't remember). The easiest and most logical swap would be an air-cooled 1776 or 1914 (Porsche engines), but that's kind of typical and my guess would be that the OP is trying for something unique (and more difficult).

You have to forfeit a lot of torque and powerband flexibility to exceed the 200HP threshold with a N/A Zetec. That isn't a particularly good plan for pushing a heavier chassis even if you installed a 6spd. Today's base Dodge caravan has 280+HP 24V V6 with 6spd auto and gobs of torque...asian offerings are similar. They give a featherweight Zetec Focus a run for their money in a straight line, so add 450lbs and figure that one out. Badass doesn't come to mind because a soccer mom will outgun you. I guess I just don't understand the point of transplanting an alternative 4 cyl econobox motor into a VW bus. It's like putting a Cobalt motor in a Honda SUV. Perhaps this engine transplant kit is the only reasonable way to bring a VW microbus into the 20th century, I don't know. I would probably leave VW bus restoration to VW fanatics who endeavor to build concours garage queens with a correct German motor. [???:)]

Do you know what engine was in the bus before the Zetec? [hah]
1. Zetec is quite torquey already.
2. ECU tune can easily increase both HP and TQ
3. I'm not a VW fanatic. I'm an auto fanatic.

Why do you think Bostig has a 9+ month waiting list on their Zetec/Vanagon conversions? A lot of these conversion have 4WD (Synchro) as well.

I think a little deeper dig will surprise you ;)

1. Zetec is quite torquey already
2. ECU tune can easily increase both HP and TQ
3. I'm not a VW fanatic. I'm an auto fanatic.

Why do you think Bostig has a 9+ month waiting list on their Zetec/Vanagon conversions? A lot of these conversion have 4WD (Synchro) as well.

I think a little deeper dig will surprise you ;)

Well,

1) forum threads suggest Duratec engine swaps to address lack of torque in Zetec (that's in the featherweight 2500lb Focus)
2) As an owner of a relatively gutless Duratec, that's just plain scary and it doesn't bode well for Zetec transplant into a heavy van.
3) Anyone who's been around dyno tests knows that chips in N/A apps are only useful for raising or removing RPM and speed limiters.
4) double digit HP and TQ chip gain for ECU tune is ficticuous except for forced induction apps. You might get a couple percent.
5) Mfrs don't leave untapped power in modern engines. OEM's tweak ECU fuel and spark curve management tables for months, not hours.
6) Factory OEM WOT spark and fuel mixture curves are not compromised AT ALL by EPA emissions goals or fuel economy calibrations.
7) A 70's VW with Ford economotor swap is a money flush. Performance, handling, safety and features won't compare to a $2K used caravan.
8) There's probably a 9 month waiting list for McRib, Kevorkian and Windows 8 beta, if that means anything.

Please don't take this post wrong because it's just a sanity check from somebody who regretted similar projects. With enough luck you will finish the project without affecting your family life, love the vehicle and drive it forever.

Well,

1) forum threads suggest Duratec engine swaps to address lack of torque in Zetec (that's in the featherweight 2500lb Focus)
2) As an owner of a relatively gutless Duratec, that's just plain scary and it doesn't bode well for Zetec transplant into a heavy van.
3) Anyone who's been around dyno tests knows that chips in N/A apps are only useful for raising or removing RPM and speed limiters.
4) double digit HP and TQ chip gain for ECU tune is ficticuous except for forced induction apps. You might get a couple percent.
5) Mfrs don't leave untapped power in modern engines. OEM's tweak ECU fuel and spark curve management tables for months, not hours.
6) Factory OEM WOT spark and fuel mixture curves are not compromised AT ALL by EPA emissions goals or fuel economy calibrations.
7) A 70's VW with Ford economotor swap is a money flush. Performance, handling, safety and features won't compare to a $2K used caravan.
8) There's probably a 9 month waiting list for McRib, Kevorkian and Windows 8 beta, if that means anything.

Please don't take this post wrong because it's just a sanity check from somebody who regretted similar projects. With enough luck you will finish the project without affecting your family life, love the vehicle and drive it forever.

I appreciate the insight. However, the Zetec I have is not one just pulled from a Focus. This is a race engine from a Lotus7 replica (Westfield) that has a few thousand dollars put into the head (P&P and valve job). At last dyno, the car put out quite a bit more HP/TQ than an FSVT.

It all comes down to a frame of reference. If you consider that the 1978 VW T2 had 67HP and 101TQ for my ~3300lb Campmobile, I think the Zetec with ~180HP and 160tq will do just fine. There are plenty of Bostig conversions out there to prove the power and reliability of a "normal" Zetec as well. Just Youtube "Bostig" and see what pops up.

Maybe after a few years when the Ecoboost engines pop up for cheap, I'll throw one of those in. The plan is to keep this thing for a while and have fun with the family.

If you don't mind me asking, what conversion left a bad taste in your mouth?

-Chris

Well,

1) forum threads suggest Duratec engine swaps to address lack of torque in Zetec (that's in the featherweight 2500lb Focus)
2) As an owner of a relatively gutless Duratec, that's just plain scary and it doesn't bode well for Zetec transplant into a heavy van.
3) Anyone who's been around dyno tests knows that chips in N/A apps are only useful for raising or removing RPM and speed limiters.
4) double digit HP and TQ chip gain for ECU tune is ficticuous except for forced induction apps. You might get a couple percent.
5) Mfrs don't leave untapped power in modern engines. OEM's tweak ECU fuel and spark curve management tables for months, not hours.
6) Factory OEM WOT spark and fuel mixture curves are not compromised AT ALL by EPA emissions goals or fuel economy calibrations.
7) A 70's VW with Ford economotor swap is a money flush. Performance, handling, safety and features won't compare to a $2K used caravan.
8) There's probably a 9 month waiting list for McRib, Kevorkian and Windows 8 beta, if that means anything.

Please don't take this post wrong because it's just a sanity check from somebody who regretted similar projects. With enough luck you will finish the project without affecting your family life, love the vehicle and drive it forever.



1. My zetec is VERY torquey and that's what there know for

2. That van is not that heavy and it's getting twice to three times the power it had stock

3. Your statement is completely wrong, there are countless members here who will agree.

4. Mostly true, no double digit gains obviously, but there are gains through out the power band

5. Majority of cars out there, there is still power left to be had, most manufactures tune for emissions, economy, and reliability

6. Not true again, while they are lifetimes better than what they used to be, especially in the newer generation of engines.

7. That's all in your opinion

8. [facepalm]



Why all the hate and misinformation? [scratch]




To the OP awesome build IMO can't wait for more pics of it and it should feel quite sporty if not down right quick for VW van [thumb]