VW Doka From Poland- Chapter 2 "That's Also Broken"

This 1989 VW Vanagon "Doka" Pickup Truck came to us from Poland, and it's in HORRIBLE condition! After months of looking for the worst one available, I'm confident we found it!
Chapter 2:
In this chapter, we get it running and driving, pretty reliably!
It's got new axles, a twice rebuilt injection pump, new timing belt, new injectors, some fresh exhaust bits, fresh oil, and most importantly- a modern stereo, operating out of a single speaker!
It turns out, everything on this car is in horrible shape and creatively cobbled together, so join us, as we un-ruin some of it!
Be sure to check out chapter 1 and subscribe for the next chapters!
Links to some products we mentioned:
Clear hose from McMaster Carr:
Fuel bulb from Amazon:
Drill powered scrub brush from amazon:
Gowesty.com

[@lGuileWilliamsl]

You tech descriptions of parts and functions gave my wife and I a good laugh. Keep up the humor! 😁

[@TheBarefootForge]

I'm glad we could share a smile with you today!

[@UkemanCad]

So glad I found this channel! 26 years ago I had a 68 weekender that was in pretty fair shape, a great project! Got married and had a kid, it was sitting so I sold it to a guy who was going to give it a good home. Now that I'm retired I need a project! Us Craigs gotta stick together!

[@TheBarefootForge]

Sounds like you’re ready for a vanagon!

[@ChronoAstynax]

I bought a 91 Carat at the end of '21. I looked like the same person did transmission things to our vehicles. Mine also has an air-cooled era tranny and the shaft was cut in half then old shaft welded back to it, and it has been a nightmare to deal with. I drove it back from Clearwater Fl, to the St. Louis area. It was a miracle I got it back. When I started it the day after I got back, one of the plastic coolant tubes broke off at the engine side and dumped coolant all over the driveway. Break lines were hitting the radiator fan. I found 6 different coolant leaks after I fixed the plastic tubes. None of the balance or expansion lines were in the top of the gas tank, it was just open to atmosphere. Both the feed line and return line leaking fuel. The Power steering rack sprayed fluid everywhere so I rebuilt that. Guy I bought it from said it was his daily driver btw. After a year of rebuilding, I started it for the first time last weekend. Hope to drive it tomorrow after some finishing touches. Love your videos, looking forward to the next chapter.

[@TheBarefootForge]

Awesome man! That sounds like quite an accomplishment! I hope your drive tomorrow goes well! I like to say “reliability has to be earned”. The last guy earned it, trusted it, and knew it- but his reliability doesn’t always pass on to you. Now you’re making it right, and earning your own- it’ll be good to ya!

[@RobertLukierski]

In my Westfalia the previous owner did very similar butchery - mostly due to the engine swap to 1.9 TDI (1Z). It is a common trick to swap the gearbox to DK (from gasoline aircooled) to get better ratios, more suited for 1.9. It is not a fast gearbox, but faster than it would have been with the original one that came with the JX (1.6) engine.

[@davidmelo6930]

And I thought I was the only one that buys junk from other “reputable” dudes and find out everything is ruined while ruining it even more…. Keep it coming bro!

[@TheBarefootForge]

No way- we LOVE the orphaned and abandoned busses! They’ve got the best stories left to offer!

[@TeeSquaredYNWA]

As a former PGH resident considering the purchase of an 87 Vanagon, your videos are both terrifying and empowering. Keep up the great content!

[@TheBarefootForge]

Don’t do it man! Lol. Your vanagon will certainly lead you on many adventures! Thanks for the support!

[@jackmehoff2961]

Thank You for sharing your video, and letting us hang out .

[@TheBarefootForge]

Thanks for coming!

[@jackmehoff2961]

I`ll be back

[@slimpickins3425]

I think im on my 4 episode today, could be 6, what a way to spend a cold cloudy Sunday! That turbo diesel makes my 80 air cooled westy look like a piece of cake! thanks for the very entertaining and informative videos!

[@TheBarefootForge]

Oh ya, it’s a whole new animal I get to learn! But that’s fine, that’s why I wanted one!

[@Smink88]

fun to watch every time. keep it up I'll keep watching as long as the mustache stays. own a doka and adventurewagen always something to do Greets from the Netherlands

[@TheBarefootForge]

Thanks Florian! There's just no good way of knowing how long the mustache will stay for, mustaches are like vanagons- they come and go, and sometimes the right one comes into your life when you least expect or need it, but if you work hard on it and improve it- it'll take you on many adventures!

[@vDC2me]

Fun to see someone else redo the shifter. What a world of difference it makes. Thanks for the entertainment.

[@TheBarefootForge]

Oh ya, especially if ya do the bushings under the car, especially when your shifter isn’t from two different cars stick welded together!

[@vDC2me]

@@TheBarefootForge I always told people shifting my van again was like reading Braille with an oven mitt on

[@vDC2me]

@@TheBarefootForge I don't know why but this guy reminds me of

[@vDC2me]

kzbin.info/www/bejne/a2SUg2d6epdqa7c

[@sgsax]

This is now my favorite car channel. Your unbridled enthusiasm and positivity really makes the horror of what you find quite enjoyable. Seriously though, as much stuff is completely broken on this, how was it running and drivable at all when you first got it? It's a testament to Polish farmer engineering, really. Thanks for sharing!

[@TheBarefootForge]

Thanks Seth! Thanks for the support and I hope you share it with friends, I’d love to continue to grow and continue to make these great videos! Heck ya man, this thing sucks- I’m excited for it!

[@rhiantaylor3446]

Glad to see you experiencing an oil-burning "bus". In Europe people seem to avoid the later PD engines because of the associated ECU, immobiliser etc. but you guys in the US kept the earlier Bosch pumped engine for a few more years than us so I guess you have more parts available than we do. Again, we sometimes see Passat 5 speed diesel trans fitted (upside down) but that leaves you with a vertically transposed H gearshift unless you can find a way to correct for the fact the box is pointing 180 degrees to its original fitment...

[@TheBarefootForge]

I saw folks doing the Passat five speed thing back in the day, so folks still do that?

[@rarerides]

Good stuff brother!! Lookin forward to Chapter 3 😎

[@TheBarefootForge]

Same! Hopefully soon.

[@RawInSeattle]

You help so much with diagnosing,,, I'm a visual learner,,, hoping for some more detail in all those repairs, you make things very logical... thanks for inspiring me to take shit apart

[@TheBarefootForge]

Thanks friend! I try to balance the overall entertainment and story with the diagnosing and mechanics, so I definitely don’t want to get “to detailed” or it loses the story and flow.

[@abnerfrost4116]

Greetings from the uk....I love the exhaust bracket the most...a true piece of art meets repulsiveness repair...❤️❤️❤️❤️😂😂😂

[@TheBarefootForge]

Oh ya, that….. Dude, that’s the tip of the iceberg. This whole car is made of “that”. Lol

[@chrisdamico9209]

Started my week off with a smile and a few laughs. Love your videos and your sense of humor. These vans have so much personality and “character”…after going through my very clean 91 carat and replacing and doing all the preventive maintenance, it runs and looks great. I can really appreciate all the work you are doing. You inspire and delight. Looking forward to chapter 3.

[@TheBarefootForge]

Thanks man! Hopefully chapter three is soon!

[@westfaliawanderings]

I have an '88 camper that had the same engine as your DOKA. After messing with it over several years I eventually gave up on it after rounds of problems involving a previously bodged cam, injector pump, the pump enrichment device... turbo.. leaks and then the final straw... overheating. I then swapped in an AHU TDI and while that has also been a pile of work to get it working right, it is so much better to drive with the extra torque and power. One good thing about all the stuff that is wrong with your DOKA is that by the time you have it all sorted out, most of the wearable pieces are going to be brand new...

[@TheBarefootForge]

Exactly! Lol. What transmission/gearing did you tie to your tdi swap?

[@neiljenkins2996]

I laughed out loud so many times watching this - you remind me of Jack Black .. looking forward to episode 3 ! 😂

[@TheBarefootForge]

Thanks Neil! I hope chapter three is a story of success!

[@montanaharkin]

The content we need! Thanks Craig! Keep it up!

[@TheBarefootForge]

Thanks Montana! What was your favorite part?

[@g.cooney6599]

Hi Craig, Love this channel! Your esprit de vive comes across beautifully! Thanks for the links to squeeze bulb and the clear tubing. Once I get my DoKa up and running I’ll take a ride down from Boston. You’re doing a good thing here! Keep Going! G.

[@TheBarefootForge]

Awesome man! Get it up and running! They’re tons of fun!

[@hooh125]

please keep doing this, I'm a new vanagon owner and probably will have many of those issues one day hahah thank you for the videos, they're very informative. Keep it up

[@TheBarefootForge]

Thanks man! I do like making them, so long as folks are watching them!

[@karloskelly]

A little bit hairy, clean up to a landing strip...I'm rolling 😂 This gets better and better. Can't wait for #3.

[@TheBarefootForge]

Well it was hairy!

[@bradrennick2919]

I've think I've found my people....This feels like watching myself replace a CV transaxle in my Eurovan. Should have taken an hour but required a month and 3 different transaxles (1st one had the right box but contained a very wrong part, the 2nd ended up breaking during install, 3rd was machined to slightly different specs than it was supposed to be so it wouldn't bend/rotate, so I ended up building a function amalgamation from all 3). Videos like this give me hope. 😂

[@TheBarefootForge]

I'm glad I can provide hope!!!

[@tonytnlvsn6659]

Cheers from SanDiego, CA keep up the awesome content brother!

[@TheBarefootForge]

Thanks Tony! I’m glad I could share a smile and a story with you!

[@Waltygo87]

Can’t wait for chapter 3. Hoping the stash makes an appearance. Maybe an engine blow up or two? Who knows! Let’s fucken go

[@TheBarefootForge]

I’m thinking there might be a new engine soon. Lol.

[@J.F.K.O]

The down function on the wiper stalk is just a white clip that needs to be removed on the stalk assembly and you have the down position. Btw nice video's love the build

[@TheBarefootForge]

AWESOME. I'll try that! Thanks!

[@Sjon777]

About the missing wiper interval: on the inside of the lever is a white clip => remove it and the lever can be moved to the interval position. I don't know whether or not the electronics are prepared for your bus, I only have experience with VW Polo's from the same period. Greetings from the Netherlands.

[@TheBarefootForge]

Awesome! I’ll have to try that! Thanks for the tip!!

[@ohhhgeee]

Thank you for the video. I’m proud owner of a 84’ diesel high top. It runs really nice but I have an injector pump that leaks pretty good. Would love to see if your friend would be interested in rebuilding another pump. I’m in Tucson, Arizona. Keep ‘em coming man, your videos are inspirational!

[@TheBarefootForge]

It took a whole lot of begging to get him to do mine, and he’s got a pile of people he’s turned down for years, so I’m pretty confident that’s a “no”. Lol. But what I’ve since found is that these Bosch VE pumps are common and you likely have a local shop that rebuilds diesel pumps with tons of Bosch ve experience!

[@eriktenarve8211]

There is a hack for you're wiper to have an intermittend position... you need to remove the White u shaped plastic thing by you're wiper stalk. And replace the relay with a relay from a golf 3 than you have an intermittend wiper function...

[@TheBarefootForge]

Awesome!!!! Thanks man! Do you know what “number” relay that would be from the golf 3?

[@eriktenarve8211]

@The Barefoot Forge there was a how to in Dutch but I cant find it any more.... I think is number 99... You have to remove te plastic cover from the steering column Love you're work btw just fuck it up until you made it... me kind of style... I've put a 1.8t 20v engine in mine rustbucket... crazy power...

[@Ford_TImelord]

Yep. Relay 99

[@DaveBrinkmann-dz7zs]

Unfortunately in Poland there's a lot talented people who do some things in completely wrong way and also it's really hard to find good shape doka

[@samtracy751]

Ahh I needed this vid. It is the motivation to get me back in the garage and working on mine. How many VW do you currently have in your arsenal? As far as engine swaps what do you recommend for a syncro. My 2.1L is okay but I want more power..the ability to cruise at 70 up hills not slow traffic to the point where an entire family in a caravan flip you off on I76 would be amazing. I realize I may not be in the ideal vehicle for that but…it does seem that unreasonable. Still smile when I drive it. Thank you for the content.

[@TheBarefootForge]

the 2.1 can be very capable when running right, what's wrong with yours? I've had 2.1s that cruise happily at 70/75mph other then massive hills. Yes, more power is sweet, but an engine swap costs $10-20K, does it bring you 20K more joy? Even with an engine swap (and i have 4 different engines in vanagons)- i avoid the highways. Its a much more peaceful drive on the back roads- maybe start there?

[@samtracy751]

I hear you. Avoid the interstate when possible. I purchased it because it is dream adventure rig. I searched far and wide for an original avoiding other peoples conversions. Ultimately I want it to be reliable (which it actually has been). I’ve been rebuilding/replacing everything. I drive it locally a fair amount and love it. I try and keep the vehicle light. Good amount of time and money into it. I suppose it is cheaper to rebuild the tired 2.1l.

[@stubenmoebel]

In Craig we trust, love your videos, regards from Germany. a nother Doka driver....

[@TheBarefootForge]

Thanks buddy!

[@mikenewman137]

Loving this, very interesting seeing the jobs you done on the engine, i will be very interested to see the engine upgrade

[@TheBarefootForge]

I’m hoping to get it reliable before I start tweaking it to within an inch of its life, but trust me…. I plan to. : )

[@alexanderdenette5101]

I am very intrigued by your hydraulic strut for the engine flap as my brace on my doka is rather rough.

[@TheBarefootForge]

I got that from McMaster. It was cheap ($20ish?) I’ll find the number for ya.

[@TheBarefootForge]

4138t77 just $27

[@robbwolf3309]

Love your VW videos!

[@TheBarefootForge]

Thanks Robb! Glad to hear it, they're fun to make!

[@knoxsyncro2988]

Splice and dice the shift rod, awesome.

[@TheBarefootForge]

It’s just made up of “things”. Some real farmer ingenuity on this car!

[@van_demonium]

Swapped an AHU into my Vanagon. Finishing up a 1Z now.

[@TheBarefootForge]

Nice! Did you do them both fully digital, or manual pumps? What’s it take to toss a 1z in? I’m thinking I may just toss that one in if it’s easy enough.

[@van_demonium]

@@TheBarefootForge The AHU I did the full swap on. It was an 82 stock diesel. Giles MTDI pump on that. It was fairly straight forward. Then in the process of looking into a tranny re-gearing,(which the AHU van now has) came across another 82 which was an unfinished 1z ETDI swap. Though I did not swap that one physically into the vehicle, a lot more was done than minimum, to keep the ETDI. In stead of running the minimal wiring to keep it TDI the PO Swapped everything and was planning for the MK3 dash swap too. I have been finishing up that process. Its been on the back burner since winter took hold up here. I will have a lot more on both of them come spring.

[@michaelraleigh-co7og]

I bought a 1985 Double Cab flatbed Vanagon Transporter that came with the seatbelts in a box. I need to know how to fit in the middle seat and the back middle seat belts...can you do a little video on belt installation?

[@TheBarefootForge]

Probably not. That’s way to specific and not really how we work around here. Sorry. Not unless you wanted to reach out and sponsor a video on the specifics of doka seat belt installation.

[@TheRedHood86]

loved each part

[@TheBarefootForge]

Awesome! A new chapter is on the way!

[@steveb6990]

Doing things twice is how I expect most projects to go (sometimes I get lucky and it's once and sometimes I get to do more learning and threes times is the ticket) and replacing a stereo that is down the list of priorities seems like good judgement for future cruising and abusing Craig.

[@TheBarefootForge]

Doing things twice is the best way to be good at it for the third time!

[@HubertusSchaper]

hello the Barefoot Forge nice to watch, I did some restoration, and still not done after almost 7 years this Summer, but I get my VW T3 Turbo Single Cab on the road, and the fuel pump has to be installed correctly, I might be able to get you the e right installment but I have from German into English. so if you are interested then I can't give you the right instruction🇺🇸🙏🏻🇳🇴🇳🇱.Greetings.Hubertus

[@TheBarefootForge]

Thanks man! I hope you get your bus back on the road this year and able to enjoy it!

[@janesecaraway3995]

I absolutely can't wait till chapter 3....and I don't know why...I know nothing about cars!! You make me laugh every time I watch!! From Montgomery al ❤️ 💕

[@TheBarefootForge]

Thanks Janese! It's a good one, it's a fun project- it's coming along!

[@Drcritique]

Hey! Nice vid. Keep going!

[@TheBarefootForge]

Thanks buddy! That's the plan! What was your favorite part?

[@mikehitchings4948]

If you ever run across a 1985 Westy in Bronze Beige Metallic - LH8U in the Pittsburgh area, can you let me know? It used to be my dad’s and I’d love to figure out how to get it back for him.

[@TheBarefootForge]

There are a few of those, probably even within our club- but sadly, I have no good way to remember and let you know when I stumble across a specific bus in the future. If you'd like to find your dream bus (though not necessarily your family's actual lost bus), I can assist in that process!

[@leroythegreat]

Any new vids on the horizon about the Doka?

[@TheBarefootForge]

Yep! A new chapter is almost ready to publish!

[@malcolmmunro4159]

You guys are so funny and good

[@TheBarefootForge]

Thats the goal! I'm glad we could share a smile!

[@JackStolz]

Craig this one was too good. Laughed my ass off and learned a thing. Thanks!

[@TheBarefootForge]

That’s the goal! I’m glad you enjoyed it!

[@theguitarmanifesto]

A feet of bodged Polish engineering

[@TheBarefootForge]

I mean, how bodged is it? I drove it to work.... The previous owners did a truly inspirational job of keeping this turd-sandwich of a vehicle on the road, i think they should be hailed as experts in the field.

[@Achilles3588]

'That's some crazy'....Lord, have I been there....

[@TheBarefootForge]

This car is made almost entirely of "Some Crazy", but its a particularly foreign variety found only in Eastern Europe.

[@Achilles3588]

@@TheBarefootForge You are absolutely correct about the retaining pins for the springs on the rear brakes from the kits being too short. Infuriating. I've thought about fabbing my own from a decent sized nail but have not had to do so yet.

[@TheBarefootForge]

@@Achilles3588 they’re available now! Still wrong in the kits, but buy a few to have on hand!

[@richardroos5965]

I've been wondering what you've been doing for the last 2 months. I see there's no end to your problems...and the time you've invested in this Project vehicle. I had to laugh when you begin by acknowledging "it's a piece of crap". I can't believe what you bought yourself into. I give you credit for negotiating down the purchase price from the previous owner. In the end you will have put out his "asking price"?...but have a good, reliable Doka, and not "a piece of crap". Is there any component still working and functional? Seems like everything needs addressed and either replaced or upgraded? I can't believe I'm hearing that you don't know how something (i.e., injection pump) works?

[@TheBarefootForge]

When it's done, it will be fully gone through and reliable. At this point, every vanagon needs that- even the one that's been owned by one family since new and is low milege, that most often just means they've forgotten or looked past maintenance and wear items for years. Every bus needs the same things, i'm must throwing them all at it, all at once. By the end of chapter 8 or so, it should be kinda functional. lol

[@montanaharkin]

This thing is gonna purr like a kitten!

[@TheBarefootForge]

Thanks man! Eventually!!!

[@cthoma17]

Why didn’t you make yourself some pins rather than using the bolts? Not worth the time it would have taken?

[@TheBarefootForge]

What bolts/pins?

[@cthoma17]

In the brake I think it was the spring retainers

[@TheBarefootForge]

@@cthoma17 Ah. Because it's actually a bit of a tricky piece to make- properly. It would have taken to long, the bolts lasted this long, they'll last a while longer. I have heard that new pins, proper pins, are in production.

[@UkemanCad]

It's a little bushy!!!LMAO!

[@TheBarefootForge]

I mean, it is…..

[@gretschmesaboogie]

If only these were cheap in the UK... have some engagement...

[@TheBarefootForge]

Hahaha. Thanks man!

[@BFVgnr]

We do it nice, because we do it twice!

[@TheBarefootForge]

Exactly! At least twice- Twice is the minimum number of times we do it.

[@nealart]

My gawd.

[@TheBarefootForge]

Progress! It’s running and driving, just still got a few kinks to work out.

[@stephsmith6421]

Laugh out loud had to spell it out for proper emphasis.

[@TheBarefootForge]

Hey Steph! I'm glad we could force the milk to squirt out of your nose, it's what I'm here for!

[@danielclunies6710]

At kzbin.info/www/bejne/i4CydX2Gg8doi68 you sound sooooo pissed at the previous owners. Lmao.

[@lefachop5755]

Your videos are awesome. But could you please... finish your sentences before cutting to the next scene... I drives me insane. lol

[@TheBarefootForge]

We have positions available as both director, and producer! They don’t pay, in fact you have to pay me- so, can you please not complain about the content I put 20+ hours into producing at a full loss? Thanks.

[@lefachop5755]

@@TheBarefootForge I'm sorry. As usual, I conveyed that badly. I didn't intend for that to be a complaint, but more like helpful, constructive advise. I'm just bad at it. Your videos are great. I've watched all the westy ones I can find. You've given me a lot of ideas about where and how to stuff new accessories in my van build. Keep up the great work. it IS appreciated by a lot of learners out there.

[@dannybutler2708]

The only thing I don't like about your channel is you bounce around to.much

[@TheBarefootForge]

Not sure what ya mean by that Danny? Between parts of the project- or literal camera stability?