Big Sky Euro

had that same starting problem on the s4...new battery and bingo! so which vehicle are you gonna bring out to the GTG's this year?

Locally, the Bus until I finish up the Caddy. Out of town I'm still gonna roll the Audi.

Air cooled love.


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cant wait for the show in billings then....

Made some progress today and over the last couple of weeks. I was in Vegas all last week, so I was really ready to get back home a do some work to get the bus going.

Before we left, I was able to get a few things done. First, I had a turn switch that needed replaced - that was a pretty straightforward swap. I used a switch from a 68-71 bus and just used the wires needed to make everything work.

Then I also needed to get the cluster lights etc. working properly. I also had a donor cluster housing that had a working brake warning light and no extra holes drilled by the PO. I also picked up some new bulbs and bulb housings

Swapping cluster housings - just swapped out gauges:







After that I wired the cluster correctly, and now I have all gauges and lights working



Next up was to tackle the problem with the bus not engaging the starter. I had first replaced the battery thinking it was a voltage or charge problem, but that didn't fix the problem.

So my next task was to pull the starter and clean/lube the solenoid. Not too hard, just tedious.







Get that hard to reach nut in the engine bay, right behind the intake plenum...



Then the lower nut, and carefully pull the starter straight out





Unscrew the two screws holding the solenoid in the assembly and pull the solenoid out. I didn't notice any real problem with my solenoid, but I could tell it needed to be cleaned out and lubed. So I took some WD40 and used it to clean the plunger while pushing the plunger in and out, then used a bit of lithium grease to continue to clean it out. When I was sure it was clean I wiped it down and then used just a bit of synthetic grease as a final lube. I also made sure to clean and lube the linkage - just a light film of syn grease.









After getting back from our Vegas vacation, I had a package waiting from Werksberg - ABS kick panels. So I was able to get the inside vacuumed and cleaned up, windows cleaned and Rain-X'd (Yes, that's my toe).









After getting it all back together, I have no issues with it starting. We (my wife and I) took it out on it's first real maiden voyage to lunch in town. We were both a bit nervous, but had no issues at all.

Next up, TMI seat cover replacements

Holy post! Nice work

I do enjoy the fire extinguisher on the seat. That was her idea, right?

And it looks more like Frodo Baggins' toe.

Haha, yeah it's a permanent fixture in the aircooled. Oh, that was my toe after 4 days of walking the Vegas strip

Not THAT kind of walking

That is a ton of stuff off the to do list. And yes the toe does look like its got the funk.


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Drove it around all day on Sunday - hauled the family around and 25 cubic feet of garden soil and plants for the garden. The kids love riding in it and it ran great, a true utilitarian vehicle