Trip follow up ... The mechanic at European Master Tech found the ground from the ignition had melted insulation.  He ran a new ground in addition to a new switch, but did not isolate the underlying cause.  He got the van running, and a test drive did not show any problems, so drove home without incident (about 8 hours).

I think the cause was using a seat heater on the passenger side seat, probably drawing too many amps (I disconnected it before driving home). Once home I also dug into a persistent issue with the dash lights not lighting, and tracing the wiring from the headlight switch found a mis-wired light wire (blue/grey) going to a speaker wire.  Fixed that and now have lights.  Perhaps that added to the problem with the seat heater?

On a related note, Richard mentioned focusing on reliability for long trips.  I am interested in a thread about reliability.  Does high reliability mean different practices from the norm?  Does it change how you do maintenance or test before a trip? Or what you add to your vehicle?

Dave B.
Boise
________________________________
From: Richard Koerner <rjkinpb@sbcglobal.net>
Sent: Tuesday, March 19, 2019 7:49 PM
To: vanagon@GERRY.VANAGON.COM; David Boan
Subject: Re: Help in salt lake

Good.  Glad you are safe and have a plan of attack.  There is a LOT of current running through that ignition switch.  Over time, corrosion on switch contacts happens, which increases resistance, and thus heat.  Eventually....Pop!  Not your fault.  Hey, 30 years is a long time!

Good luck David!  Thanks too for reaching out to the Vanagon List....let's keep this thing alive!

On Tuesday, March 19, 2019, 4:39:33 PM PDT, David Boan <dboan@OUTLOOK.COM> wrote:

Thanks very much.  Found European master tech and they will fix in morning.  Fortunately have relatives here so picked a good spot to quit.  I think I will start carrying spare ignition switches, but wonder why it shorted out.

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________________________________

From: Richard Koerner <rjkinpb@sbcglobal.net<mailto:rjkinpb@sbcglobal.net>>
Sent: Tuesday, March 19, 2019 4:40:52 PM
To: vanagon@GERRY.VANAGON.COM<mailto:vanagon@GERRY.VANAGON.COM>; David Boan
Subject: Re: Help in salt lake

There is a Motel 6 within walking distance from this shop.

Hopefully it is just something as simple as a fried ignition switch; part costs about $15; takes about 1/2 hour to remove and replace.

On Tuesday, March 19, 2019, 3:29:33 PM PDT, Richard Koerner <rjkinpb@sbcglobal.net<mailto:rjkinpb@sbcglobal.net>> wrote:

And here is another shop in Ogden:

Vee Dub Service
880 West 2100 South
Ogden, Utah 84401
Phone: 801.392.0212

Owner: Ed

Type Of Shop: VW Repair & Parts
Will Work On: Water-cooled but not Eurovan

Northern Utah

On Tuesday, March 19, 2019, 3:17:54 PM PDT, David Boan <dboan@OUTLOOK.COM<mailto:dboan@OUTLOOK.COM>> wrote:

I just broke down off of hwy 15 in Ogden.  Smoke came from the ignition and the engine quit.  Any advice where to tow to?

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