Why bostig v2.0? - Bostig Engineering - VW Vanagon Engine Conversion Systems

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5year/50K mile warranty: The Bostig Conversion has the longest warranty of any conversion available, and has been proving itself ever since the first prototype was up and running. The v2.0 is even simpler, with an even lower parts count. Less parts means less chances of failure to begin with, but we also back it up with the best warranty and risk management in the marketplace. In addition, no single part of the conversion costs more than 650 dollars(including the average price of a low mileage zetec engine including shipping). In the event of a worst case scenario(an engine failure out of warranty) the hit is minimal, and several times less costly both in terms of time and money than the same scenario for any other conversion. The risks are lower with the zetec to begin with as well, firstly the zetec has a significantly lower frequency of engine problems than any of the other options. Secondly, the zetec's production numbers are substantially higher than the other options. These two combined factors are why used zetec engines can be had with a small fraction of the miles at a small fraction of the price of an average subaru ej25 for example. Warrantying an engine that costs a few thousand dollars is extremely risky, add in the the higher frequency of problems, and you have the short warranty period seen from vendors that sell rebuilt engines or prep engines for use in conversions. Limiting your risk by the use of the engine with the best reliability index available for vanagons, plus the long warranty on the conversion system parts is a very effective way of NOT putting all of your eggs in one basket.
Engine management update capability: We are the only conversion manufacturer that matches engine management firmware to our conversion hardware. Other providers counter our capability with claims like "The automakers spent millions on development, and it should be kept stock", and then of course they modify the intake, exhaust, headers, and other systems to make it fit in a vanagon. But what makes a stock system good is the fact that the tune matches the actual hardware implemented. Like the OEMs we follow this approach. Vendors that do not are either displaying a fundamental lack of understanding of the important relationship between the ECU programming and the hardware, or they're trying to excuse themselves from lacking this capability entirely, and hoping their customers don't know any better. Our holistic approach is the proper way of implementing a powerplant from one vehicle to another. You *can* run on a stock tune and it may be fine, but our customers are seeking our expertise in their purchase, and with that responsibility we must provide what is best, not simply what the customer asks for. We offer more than what is required to make a sale, we offer the best capabilities given the limits of technology and the money involved. Our update capability allows customers to download new tunes from our support section as they are improved over time to offer new capabilities like e85, or to allow for bolt-on operation of superchargers and turbochargers, or any other modifications down the road that a customer might want.
E85 ethanol out of the box: As a result of our engine management update capabilities, we can now offer e85 ethanol operation right out of the box. We are the first to offer this functionality to conversion customers, which will allow for not only a dramatic reduction in vehicle emissions(95% decrease in hydrocarbon emissions alone) but also customers can benefit from e85 propagation initiatives which usually equal e85 fuel at prices much lower than gasoline. Additionally, with the addition of a turbo or supercharger the real benefits of e85 and it's knock suppression capabilities come alive in the form of substantial increases in power and torque, while only taking a 14% or so fuel consumption hit vs. gasoline in the zetec.
Digital Dash/logging: Another result of our tech-savvy leading edge approach is we offer customers full high-speed datalogging and digital dashboard functionality as standard. No other conversion offers either, they may offer OBDII(low speed, generic parameters) functionality, but we offer unmatched functionality in both of these areas. Normally you would find this only in top-of-the-line aftermarket engine management systems, but we do it with the bulletproof reliability of the factory ECU and engine management system. From being able to monitor high-speed realtime data from every metric the engine computer sees, to also being able to log as you drive, it is possible for a customer to send us their datalogs so we can see and replay everything they do to aid in tune development, it's almost as good as being in the passenger seat.
Reading Break: If you haven't said "cool" to yourself yet after reading the features up to here, please go take a nap and come back later, you must be in a bad mood.
Failure Mode Effects Management(FMEM): In the event of one or more sensor failures, the ECU will initiate FMEM to maintain drivability. You may suffer reduced performance, but the failure won't leave you stranded.
Hardware Limited Operation Strategy(HLOS): Up till now all of these cool little features sound all well and good, but what if the computer fails.. then what? If it has failed then it can't do anything right? Well no, not exactly. There is actually some protection should the ECU itself fail. The Hardware Limited Operation Strategy kicks in if the ECU fails... well actually the HLOS circuitry is really the only stuff left if the ECU fails! BUT the HLOS is alternate circuitry that will still provide minimal engine operation functions if the ECU encounters a serious failure or malfunction.
Fully Prewired, Plug & Play: As the originators of the very first turnkey vanagon engine conversion, we made sure that the Bostig v2.0 Conversion System is just as easy as a turnkey, and the wiring harness is fully assembled, wired, and plug and play, no wire splices required to van wiring.
Unlike the competition, we are the only conversion provider that manufactures a custom fit purpose built harness from brand new parts. Not only does the quality of our splice-free harness surpass any of the competition, but because they are designed and built by us, the consistency level is also unmatchable by the competition. In the long haul, this consistency and quality is key.

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Best engineered option available: Because we designed the Bostig v2.0 from the ground up ourselves, you can count on the attention to detail, and stellar quality that we're known for. We are the only provider that designed the system entirely in-house and with advanced tools like our CAD software of choice, Solidworks. We know every part of the conversion inside and out to the last little detail, because we either designed or selected every component ourselves. At every stage in design, we made sure that the best possible technologies, ideas, and design methodologies were employed to deliver a solution of unmatched forethought, efficiency, and reliability. Our conversion system is comprised of the combined best practices from all spheres of our expertise, and with greater breadth and depth than our competition, it is easy to see the differences in quality and in coverage. Additionally our conversion is the only second generation conversion. We went through an entire lifecycle of the first design, and have now re-released a redesigned conversion based on improvements with our ever increasing capabilities and understanding of what it really takes to build the most reliable conversion system possible. Our pace of development is also considerably faster than our competition despite our much larger scope in design areas. Some conversions have been around for 12 years and longer, address less than a third of the areas we consider and design for, and yet in less than 4 years we have already been able to offer the first and only turnkey conversion system to be developed from scratch in the market, and now the first and only second generation conversion system in the marketplace.
Ultra-low cost of ownership: As a result of our choice of engine, parts are available everywhere, and are extremely inexpensive. Additionally, because of the careful way we've designed our kit, all wearable components are readily available and inexpensive should they need to be replaced. We spent countless hours finding pre-existing components to suit our needs so that our customers will be able to maintain their conversions easily and inexpensively no matter where they are... or aren't.
Power and power potential: We start at a dyno proven 130hp for the base install(beware, other power numbers in the marketplace are estimated or factory crank numbers, we remain the only vendor to use a chassis dyno to prove our power claims). Additional power options, along with both an upcoming Bostig turbo kit designed for all owner/operators and existing aftermarket options(not for those without modding/tuning experience) to bring power up to the 230 range safely. The benefit of going the Bostig route is that you can buy a base conversion today, and then, if in a year or two you suddenly decide you want substantially more, you can do so without wasting your investment. In fact when comparing to a 3.3L SVX conversion, you don't even have to make the same power to achieve better performance since the Bostig weighs so much less, and gets better gas mileage when your foot isn't in it. The whole package will still cost less than an SVX conversion as well, because paying extra for scarcity DOES NOT add value to a conversion. This is not even considering the cost of parts or maintenance. In fact, if a customer chooses(and has a huge wallet), with upgraded forged internals, we can produce 600HP from this amazing little engine, although we'd have to look for a weddle replacement for the poor transmission pretty quick!
Wide torque band: We wanted a torque curve that provided not only additional power above the waterboxer's peak, but below as well. The Bostig has an extremely fat and usable torque curve which is what makes the Bostig vanagon so drivable. Go see the dyno chart below:

Note: This is the chassis dyno (real world, not factory crank or estimated HP) readout of our finalized Zetec setup vs. a very healthy stock 2.1 waterboxer. Notice the dramatic size and area difference of the Zetec torque curve(red) as compared to the waterboxer(orange). Also note that the Zetec makes more power(green) than the waterboxer(blue) everywhere in the power band, and when the boxer starts to fall off, the zetec continues to pull, which is what gives each gear much longer legs(much larger range of usable speed in each gear).
Reliability: The Zetec is a Non-interference engine, so if your timing belt ever breaks, you're only out $60 and about 1 hour to change it. The engine is also fully internally balanced, and has a history of extremely high output applications. We've been trying to literally destroy our prototype's engine, but we have not been able to do it despite tens of thousands of miles of all-out abuse, low oil conditions(we ran 11 months on one oil change never checking or adding to measure the effects), induced component failures, controlled engine fire, and even an unintentional rollover. No dice. If Brady can't kill it, then neither can you;that's one of the reasons why Zetec engines are so low cost, they do not fail in the stock application and demand for replacements is very low. The zetec also has the best reliability index of any engine used for vanagon engine replacement. The kit components are well designed and built for long life. We build everything like it was for our own vehicles. Nobody else offering a conversion kit goes to the level of detail and quality in their implementations as we do.
Efficiency: Space efficient. Cost efficient. Fuel efficient. The power-to-weight ratio and power output per cubic inch of the Zetec is higher than any other engine conversion available. Not only does this allow the Zetec to put out quite a bit more power and torque than the larger displacement 2.1L boxer, but its emissions(both driving and total) are lower as well.
Simplicity: The Bostig v2.0 is the single simplest conversion available for vanagons. Simple is good. With less moving parts, less non-moving parts, fewer wires, fewer gaskets, and fewer sealing surfaces the potential for failures of all kinds is lower than any other conversion by miles. This is not an accident, the Zetec was selected partly for this single attribute. The less there is to learn, the more likely one is to learn it, the less there is to go wrong, the less likely something will go wrong. The KISS principle in full effect.
Completeness: You don't need to figure out which extras to buy or build. You don't need to figure out where and how to source parts. We either provide the part itself, or provide a standard procedure to source every single part in the system with an eye to both ease and cost effectiveness. We are the only vendor that provides this level of completeness. We want to make sure that our customers have everything they need to enjoy, maintain, and really put some (s)miles on their vanagons with the least amount of trouble possible (wow, that is so UN-VANAGON-LIKE!). Add to this enhanced power, drivability, and capability and you have a unbeatable and well rounded upgrade. Unlike our competition, we don't stop with the engine mechanicals, we provide an engine management solution, and operator information to complete the picture.
Low vibration: Many folks with VW inline engine conversions complain of harshness, noise, and vibration, but our kit has very little vibration, mostly due to the smooth running of the Zetec (which is internally balanced extremely well to tolerances usually found only in high-end cars like Porsches and M3s), and is preserved due to our attention in having every machined rotating part balanced to the same high tolerances. We also stabilize and isolate the zetec with a beefy integrated adaptation and mounting system, and since the mounts were sourced based on performance and availability(from a late model taurus), they can be had off the shelf for thirty dollars each. The only people that still naysay and claim the Zetec is prone to more vibration than other options are people that have never driven one.
Maintenance independence: We felt that if we were to buy an engine conversion kit, we'd want to be able to maintain it without always needing to go back to the kit manufacturer or dealer as it's not always possible or cost effective to do so. Instead, it made more sense to us to utilize the massive parts and support-infrastructure already in place for the Zetec engine. We have spent substantial extra time to develop our kit with this "exploitation" idea in mind, and we are very proud of the results. No other option can match the level of parts availability and low parts costs that the Zetec conversion enjoys. And because of the simple design of the Zetec itself, things that you may not have ever thought you were capable of (a water pump change, or timing belt perhaps) are not only fast and cheap($50 and 10 minutes for the water pump) but doable by people with no previous experience with no risk of damage(the Zetec timing belt is the easiest, fastest, and cheapest to replace of all the possible options). From Alaska, Argentina, Australia.. the list goes on, because our conversion is based on a huge "world motor" program, you can always maintain your Zetec.

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General

	Bostig v2.0	Subaru EJ22	Subaru EJ25	Subaru EG33	VW Inline	TDI
5yr/50,000 mile warranty
>85% of the cost of conversion spent on new parts
Single party development
3 zone development method: engine mechanicals, engine management, and operator information
Average install cost around 5 thousand dollars
Stainless steel component upgrade package available

Engine Mechanicals

	Bostig v2.0	Subaru EJ22	Subaru EJ25	Subaru EG33	VW Inline	TDI
Non-interference
Fully closed deck
Low mileage engines(<30k) for under 600 dollars commonplace
Less moving and non-moving parts than original engine
Lowest hose count
Based on a highly successful " World engine" program, more than 3 million engines produced, potent economies of scale
Full capacity oil pan does not reduce departure angle
Increase in vehicle weight from conversion less than 60lbs
Import numbers higher than original engine
Never unseal the longblock, no internal work, deal only w/ complete engines
Highest engine reliability index of any conversion
Steel oil sump

Engine Management

	Bostig v2.0	Subaru EJ22	Subaru EJ25	Subaru EG33	VW Inline	TDI
Engine management tailored to exact hardware configuration
100% Brand new, never installed, purpose-built wiring harnesses
Engine management updates via email and web
Never any diagnostic trouble codes for missing subsystems
Lowest wire count of any conversion
ECU and main wiring self contained in weatherproof housing to free space under rear bench
Comes Bio-fuel capable

Maintenance

Operator Information

Upgradability

Drivability

Bostig v2.0

Subaru EJ22

Subaru EJ25

Subaru EG33

Parts available everywhere, including mid-western US, central/south America, Africa, Europe and Australia

Largest existing parts infrastructure of any conversion

Least expensive parts of any conversion

Lowest maintenance times of any conversion

Replace/refresh the engine for under 600 dollars

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