Throttle cable. I spend 3 hours searching the Internet looking for throttle cable material before I stumbled on a Chevy engine swap site that mentioned Home Depot. 1/16” diameter, 9 strand twisted into one cable, itty bitty wire rope. Stranded wire comes in two configurations. 1x9 & 7x7 IIRC. 1x9 is what you want. Home Depot has it. $0.27/ft.

Jim

From: Larry Alofs 
Sent: Monday, May 13, 2013 6:14 AM
To: Jim Arnott 
Cc: vanagon@gerry.vanagon.com 
Subject: Re: ABA into 1.9 Vanagon was coolant overflow fears and thoughts

?? 
20' of 1/16" 1x9 galvanized wire from Home Depot
??

On Sun, May 12, 2013 at 11:17 PM, Jim Arnott <jrasite@eoni.com> wrote:

  On May 12, 2013, at 5:28 PM, Stuart MacMillan wrote:

    And you can add a turbo too!  The folks at FAS have an elegant 2.0
    package,
    but it's way too expensive for me.   Where is the documentation,
    parts, etc.
    for a junkyard DIY ABA engine conversion?  I don't want to fabricate
    everything myself and figure out the wiring, plumbing, mounts,
    exhaust, etc.

  It ain't a kit. As the late Bob Hoover said, YOU are the mechanic in
  charge.

  Photos:

  Work in Progress: http://tinyurl.com/czp7tvl (Note: The orange bus in
  the first couple pics was the model. That is an ABA into an '82 diesel)
  Finished product: http://tinyurl.com/bvrra5g

  Parts:

  '96 92k mile ABA complete from a Trek Jetta that was junked due to
  immobilizer problems
  Engine wiring harness from same '96 Trek Jetta
  ECU
  alternator
  hoses and coolant reservoir
  timing belt & tensioner
  windage tray
  6" of the exhaust header pipe from the donor

  '83 Diesel:
  carrier bars
  engine mounts
  motor mounts
  oil pan
  oil pickup
  oil filler
  dipstick & tube
  exhaust mounts
  bell housing
  bell housing dust shield
  bell housing to engine attachment bolts
  transmission input shaft seal
  either a diesel input shaft or shorten wasserboxer shaft 10 mm
  transmission to bell housing gasket
  flywheel
  clutch & pressure plate
  throwout bearing
  starter
  engine compartment cooling hoses
  thermostat housing
  steel engine cover

  '86+ 2.1 Vanagon:
  intake snorkel

  '98 VR6 Passat
  water pump pulley
  DLC & a piece of the harness (about 6" long)

  ''98 Ford Escort Zetec
  Air cleaner

  16" 2 3/4" aluminum irrigation pipe
  Intake hose from some junkyard Audi that was the right shape.
  Miscellaneous cooling hoses from NAPA. (numbers to come)

  20' of 1/16" 1x9 galvanized wire from Home Depot
  20x1032 serpentine belt (no A/C, no PS.)
  120amp Cole-Hersee continuous duty relay for the house batteries.

  Exhaust system:
  custom fabrication
  34" 1.75 dia secondary pipes dumping into a 2.5" collector to a OBD II
  extra load universal cat to a 700 oval 3 pass muffler and 3 hours of
  labor.

  There are probably additional parts/pieces, but that'll get the engine
  in the hole. The most challenging part of the whole process was
  marrying the DigiJet Vanagon to the ABA's Motronic engine management
  system. You only need three wires:  Power, switched power and ground.
  Getting those three wires hooked up to the the right places took an
  ASE master technician/mechanic. After he's recovered a bit, I'll get
  the documentation.

  The only downside to this conversion is now I have to haul 2 Bentleys
  around. Vanagon & Jetta. Small price to pay. It has transformed my
  Adventurewagen into a real car. And I picked up 3 mpg as well.

  Jim