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 VW Syncro Westfalia - Build Log with Pics

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n16ht5
Meberhar
Relaytech
Inspector
mamacone
DEisenhard
Shane
Hodakaguy
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Shane




Posts : 843
Join date : 2009-08-04

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/1/2012, 9:08 pm

Very interesting .. I have lots of questions but will wait and see lurk what you do. I am sure they will get answered ..
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Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/1/2012, 9:13 pm

Shane wrote:
Very interesting .. I have lots of questions but will wait and see lurk what you do. I am sure they will get answered ..

Feel free to ask away thumb

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/3/2012, 5:45 pm

Update.

Time to install new output seals.

I've read where some people are able to remove the output stubs by tapping with a hammer...these are on tight and required a puller. I added a thick washer behind the puller to keep from damaging the threads on the end of the output shaft (Red Arrow).

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A seal puller made quick work of removing the seals.

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Installing the new seals

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...more powder coating.

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Freshly coated output shafts installed :-)

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Now to remove the shift shaft seal and install a new one. Well I removed the seal but there is a plastic bushing behind it that was either broke or got broke while removing the seal. Hmmmm......

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I called Daryl at AA Transaxle to ask him about removing the bushing. He said I could place the trans in nutral and remove the shaft from the trans by removing the reverse switch assy from the opposite side. Once the shaft was removed I could break the latch tab off the bushing and remove it from the trans. :-)

Removing the shift shaft

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Broken bushing removed. A replacement will be installed shortly.

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Got the POR15 applied ( 3 coats) as well as the POR15 Top coat. I will be using Waxoyl (or similar) to top coat the entire underside and down in the nooks and crannies. Living in the desert it should keep it in great cond for years to come :-)

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/18/2012, 1:10 am

Been working a lot lately so I haven't had a chance to work on the bus much. Did manage to get a little work done today though. Installed the new input and shift shaft seals. Now on to the starter.

I decided to install a Diesel TDI starter so I will have a reliable modern starter that will crank the 2.5L over without a problem, as a side benefit this starter is self supporting so you don't need to use the support bushing in the bell housing that is prone to wear.

I ordered a Bosch SR0408X starter and a Westy Ventures adapter plate, now to install them.

Starter and adapter plate.

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Since I'm installing the setup in a Syncro the Diff Locker brackets need to be trimmed. I trimmed the brackets (at the red arrows) so they will clear the starter and powder coated them black.

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With the adapter plate temporarily in place the starter is test fitted. You need to trim a small notch in the starter so the upper mounting plate nut has room to seat. (at red arrow)

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Starter notched....

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Installing the Diff lock brackets, here you can see why the notching is needed for clearance.

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Another angle. Here the starter is bolted up tight, I applied a thin layer of Ultra Grey gasket maker to the mating surfaces to keep water out.

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You need to notch the corner of the diff actuator to clear the edge of the starter.

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Assembled, it's a tight fit but it all goes together.

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Shift assy installed along with new rubber shift boots.

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More to come

Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/22/2012, 7:01 pm

Today's progress.

Pulled the cross shaft bushing.

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Using dry ice and denatured alcohol to shrink the new cross shaft bushing for install.

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New bushing in place.

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The new cross shaft was the same as the old one, welded good on one side and the other side was almost not welded at all, very little penetration. I've read and been warned where the arms are prone to break off since they are really only welded on one side. Since I will be running a higher than stock pressure plate this will need attention.

Here's the side that's welded from the factory.

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And the other side....

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Now to take care of this problem before installing the new cross shaft. I placed a clamp on the outer edges of the arms before welding. I welded the outside first so the arms would want to pull towards the clamp, then across and to the inside edge. I measured the gap between the arms with a dial caliper before welding and after..no change :-)

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Cross shaft with new bushing kit, ready to be installed. For a long time the bushing kit and seals were non existent, you can now get a new set through VanCafe. :-)

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Cross shaft installed.

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New clutch slave cylinder bolted up with fresh hardware.

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New bearings going in the dry ice solution to be installed in the drivers side carrier.

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Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/24/2012, 7:46 pm

Small amount of progress after work tonight.

Removed the rear bumper and tail lights in preparation for undercoating. This bumper won't be going back on the bus :-)

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Removed all the "bolt on" items in the engine bay. Lot's of cleaning and sanding now :-(

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Started on sanding....Lots of prep work to go still. There are a few areas that I will spot treat with POR15 before shooting the undercoating. Can't wait to get the undercoating applied....that will be the turning point and things can start going back together again :-)

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Drilled out the froze cotter key on the drivers side axle, now I can finish putting the carrier together.

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More to come.

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/30/2012, 6:45 pm

Time to apply the Undercoating.

So far my father and I have spent about 9hrs just on prep of the engine bay getting it ready to coat. I spent 3/4 of the day today under the bus cleaning and prepping. I removed any POR15 that didn't have a secure bond.

Starting to mask things that shouldn't get coating on them.

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More Masking....You can get free slip sheets of cardboard at Costco, they work great for things like this :-)

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Time to do battle with the undercoat gun. I'm using a Eastwood gun and Wurth undercoating.

The gun...

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Ok....Lets go at it.

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Not Bad :-). I would have liked to apply another coat but I ran out of undercoat :-(. The gun worked great but you have to be careful tipping it upside down, the undercoating will flow into the air passages and the gun stops working pretty fast. Had to stop about 3/4 of the way through and clean the gun so I could finish up. I ended up applying 4 bottles of Undercoating to the engine bay/wheel wells.

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Now I will apply cavity wax to the frame and any nooks and crannies. Then install the fuel tank, suspension etc.

Going to start looking like something soon!

More to come.

Hodakaguy
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Shane

Shane


Posts : 843
Join date : 2009-08-04
Age : 48
Bike : 09' DR650SE

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime9/30/2012, 8:36 pm

Perfection is in the details. Nice work! thumb
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mamacone

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/1/2012, 4:53 pm

Looks like you are having more fun than a motorcycle ride would be Evil6
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/1/2012, 9:21 pm

Shane wrote:
Perfection is in the details. Nice work! VW Syncro Westfalia - Build Log with Pics - Page 2 5543

Thanks!

Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/1/2012, 9:22 pm

mamacone wrote:
Looks like you are having more fun than a motorcycle ride would be VW Syncro Westfalia - Build Log with Pics - Page 2 391375

I'll be having a TON of fun with it once it's done...the thought of using it keeps me motivated to work on it :-)

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/1/2012, 9:22 pm

A little work on the fuel tank today.

Removed the sending unit from the tank...crusty!

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Inside the fuel tank I found the rubber return line disintegrating and leaving chunks of rubber everywhere.

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The old sender next to the new unit

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One last piece of rubber clinging to the return hose.

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The seal on the roll over float valve is toast.

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The fuel sending unit bracket was actually in good cond, I was figuring on much worse so I already had a replacement Stainless Steel unit on hand. Since I have the SS unit I will install it.

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So time to find a replacement piece of hose for the return line in the tank. Easy you might say? Well it needs to have a 30R10 rating on the hose for submerged service, most of the fuel line you find at the auto store is 30R9 rated for fuel injection but won't hold up to submerged service since the outer layer of rubber is different than the internal rubber compound, it would look like my old hose after a short while. Many calls later I finally located some Gates 30R10 hose :-) Now to get the proper fuel line clamps.

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More work tomorrow.

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/2/2012, 7:14 pm

Been helping out a friend the last couple days with his bus....now it's time to get going on mine again.

I ordered a fuel tank Re-seal kit from Van-Cafe but it came with all carbon steel screw style hose clamps. I would prefer to install the new hose with OEM crimp style clamps....now to find some!

After calling around to a dozen auto supply stores, industrial supply stores etc I finally hit on the idea to call the local BMW car dealer....no way they would re-install a customers fuel hose with a screw style hose clamp. Bingo...they had exactly what I was after :-)

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Installing the 30R10 internal fuel return line on the new sending unit.

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Time to install the new backing plates and gaskets.

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And the new Sending unit

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I didn't care for the vapor return line that was included with the kit either. To me it felt like soft vacuum hose with a cloth braided exterior, It might be good stuff but seemed like it might deteriorate to quickly. Off to the auto store to get some Gates vapor return hose.

Gates on the left, VanCafe on the right.

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I couldn't find the correct size crimp clamps for the vapor return line so I ended up using the supplied screw clamps.

New hose in place

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Time to sand blast and powder coat the fuel tank hose retainer

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Before....

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And After. I also installed larger washers than the kit was supplied with to help even the pressure out on the sender/gasket and hopefully get a better seal.

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I re-installed the original firewall insulation/retainers that go behind the fuel tank. It was in really good cond so I'll re-use it :-)

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Hopefully there will be a bunch of progress in the next few days :-)

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/3/2012, 7:16 pm

Today's progress

Started this am by installing the engine heat shield/exhaust hanger. Here I'm installing the stand offs for the heat shield.

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Heat shield installed

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Time to clean up the exhaust mounting surface. This is a 3M Roloc Bristle disk, these things are the ticket for cleaning up gasket surfaces!

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Before....

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After...

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Installing the Rocky Mountain Westy Stainless Steel exhaust. The quality of this exhaust system in top notch, Everything fits perfectly with no binding anywhere. :-)

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Nice thick flange..

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The one small defect...whoever welded the muffler on the cat welded it with the "Magnaflow" upside down! The other side of the muffler has the logo printed the other way. Minor thing but....Grrr...

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Time to clear out the interior to get ready for the harness/engine install. First up...remove the rear seat.

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This is the cover for the OEM rear heater. The heater will be permanently removed and a Propex propane heater installed in it's place.

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The factory heater unit. When I first purchased the bus the rear heater core was weeping, I removed the core and plugged the lines. Now it's time to remove the rest.

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Here I marked the rear seat assy to be cut later for wire harness clearance.

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Upon removing the rear seat the last bolt was froze solid. I ended up having to use a impact screw driver to remove the screw....which ended up tearing out the well nut on the underside of the bus, well that's just great. This will have to be fixed before proceeding.

Here's the damaged well nut. In this picture I drilled out the hole to be slightly over sized.

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This is a Rivet Nut Setter tool. It works like a pop rivet but leaves a crimped nut on the underside that you don't need a backup on. Use can use steel or aluminum nuts.

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Installed...

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And the underside...you can see how it crimped itself in this pic.

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Time to install the harness. I had the harness modified by Small Car Performance, since then I've read where a lot of people have had issues with them so I hope mine is done correctly.

This engine is a 06 which has the immobilizer built into it, since I won't be using the original key etc the ECU had to be tricked into thinking it has all the proper clearances to start.

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The hole where the harness feeds into the body is small, the only way to get it through the hole is to disconnect everything on the ECU end. A couple of the relays are assembled into a large carrier that won't fit through the hole so I ended up having to remove individual wires. Here's my wire diagram I made up so I can get it back together again :-)

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Disconnected and ready to feed through. I had to remove the insulation under the bus again to get clearance to push the harness through.

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Wiring and grommet through the hole, the grommet is twice as big as the hole that it's needing to fit into and Small Car trimmed it in a weird way. For the price of the harness you think they could have supplied a correct size rubber boot.

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The underside of the boot. This is as far as you can get it into the hole. A little further and it would fit like it's suppose to.

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Black RTV/Sealant to make sure the boot stays in place and is waterproof.

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I needed to work on something else while the sealant dried so it's time to test the fuel tank. I want to make sure there are no leaks on any of the new seals/sender before installing the fuel tank and having to remove the engine/trans to get to it again!

The jury rigged test setup :-). The wifes car is on empty so I will fill the tank with gas and test for leaks, then drain it back out and pour it into the car.

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Tank is now full and no leaks! Once full I measured the resistance of the sending unit, then measured it several times while draining the tank. Wanted to make sure the new sender was working correctly....yep, working perfectly!

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My father helping drain the fuel tank :-)

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Time to install the urethane bushings in the drivers side trailing arm.

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Just about done...

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Done

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Well that's it for the day.....more tomorrow.

Hodakaguy
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Shane

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/3/2012, 7:43 pm

You may already no this but I see the green D-check connector is unpluged like it is supposed to be. We get a lot of subys in with this conector pluged in. Its the green connector in the last pic before you stuck it through the body. Just ssome fyi.
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/4/2012, 5:31 pm

Shane wrote:
You may already no this but I see the green D-check connector is unpluged like it is supposed to be. We get a lot of subys in with this conector pluged in. Its the green connector in the last pic before you stuck it through the body. Just ssome fyi.

Thanks for the tip VW Syncro Westfalia - Build Log with Pics - Page 2 5543

Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/4/2012, 5:32 pm

Got a late start on the build today....and re-installing the fuel tank took a LOT longer than expected.

The fuel tank is a TIGHT fit. You have to use pry bars to remove it from the bus and you need them to re-install it as well. Going back in with the tank you have new hoses and a new sending unit to worry about so that slows it down some more. We finally eased the tank into position then couldn't find the hardware for the straps....another trip to the store :-)

Finally the fuel tank is installed :-)

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A custom tweak to the sheet metal for more fuel hose supply/return clearance.

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Suspension starting to take shape. New GW 2" Lift Spring in place.

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Before I can finish assembly on the suspension I need to install the metal fuel tank filler pipe. Some how this part had slipped past me when I was doing media blasting, a quick inspection showed rust bubbles on the back side of the tube so it will need attention before assy. Since the pipe sticks into the tank and is in direct contact with fuel I decided to leave the OEM coating (which is in good cond in that area) where it enters the tank. I will paint the rest of this piece since I'm not sure what the oven temps for powder coating would do to the factory coating.

Blasted (Ends covered so I can keep the OEM coating in those spots).

VW Syncro Westfalia - Build Log with Pics - Page 2 Phone1_zpsac992905


Primed and painted a textured black

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Picked up some new hardened hardware for the shocks today as well :-)

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Hodaskgauy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/5/2012, 5:53 pm

Installed the fuel filler pipe this am, got a late start since it was 28 deg this am....Brrrrrrrr.

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Filler assy back together again

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Getting ready to install the shock, a 7 way adjustable Fox unit. I'll be installing limiting straps with custom adjuster/mounts as well, I'll do that after it's back on it's wheels and the engine is installed.

Here I'm applying a think coat of wax to keep the shock in good cond, I'll re-apply a few times a year.

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Installed. :-)

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Now to clean up the brake hardware. This is a Harbor Freight Ultrasonic cleaner, it works pretty good! I use full strength Simple Green as the solution...place your parts in the bath and run it through a few cycles. Not the best Ultrasonic unit on the market but the price is right.

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Before.....

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And fresh out of the cleaner.

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Had to get some work around the house done today so I stopped there. More progress tomorrow.

Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/14/2012, 7:45 pm

Progress has been slow lately, been working a lot of overtime.

Today I assembled the brakes on the passenger side and re-installed the tire.

Parts cleaned up, new wheel cylinder....going back together.

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Hard line and new Stainless brake hose installed.

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My friend Mike torquing the rear axle nut to spec while I snap a pic :-)

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Sitting on the wheel again....oh yeah!

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Installed the drivers side trailing arm.

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That's all for tonight :-)

Hodakaguy
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Shane

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/14/2012, 9:39 pm

Those are my favorite tires. You cant beat the BF AT's. I have ran several sets on diffrent rigs and they always worked well.
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Inspector
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/15/2012, 7:20 am

He's got them on backwards!

Evil6
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/15/2012, 12:33 pm

I like the looks of the lettering on the outside while its clean and new....but it doesn't stay that way long :-)

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Relaytech

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/19/2012, 9:23 pm

I always put the the white letters on the inside too! Why give the tire company free advertising!?!
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Shane

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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/20/2012, 11:26 am

Call me old school.... but I like the white letters out... and I dont have a reason to justify it. dunno
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/28/2012, 4:44 am

This is great! Your van is looking really nice. I started mine a while back and am in pretty much the same point as you are at the moment. It really is looking good! Keep up the great work.
Cheers,
Mike
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime10/28/2012, 6:25 am

Meberhar wrote:
This is great! Your van is looking really nice. I started mine a while back and am in pretty much the same point as you are at the moment. It really is looking good! Keep up the great work.
Cheers,
Mike

What ya building? Subaru conversion?

Hodakaguy
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PostSubject: Re: VW Syncro Westfalia - Build Log with Pics   VW Syncro Westfalia - Build Log with Pics - Page 2 Icon_minitime

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