Limey, The Syncro 16 Westy. Was 2.5TDi, Now 2.2 20V Turbo!

offroad. · Posted: Sat Sep 17, 2011 8:54 am Post subject:

that is classic. seeing limey back as a tin top hit home how good they look naked so to speek.

" wouldn`t it be cool if you could design some sort of sliding mechanisum so the roof panel could be swapped out. like a cartridge design. water tight but just slide off you high top and slide in a tin top or pop top."

OOPS did i say that out loud. Embarassed

SyncroGhia · Posted: Sat Sep 17, 2011 8:59 am Post subject:

SyncroGhia · Posted: Mon Sep 19, 2011 5:38 am Post subject:

Looking a bit different with a quick test shot...

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MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Sun Sep 25, 2011 10:38 am Post subject:

I grabbed some time over the weekend to buy new rear wheel bearings for the modified rear hubs for the disc conversion.

They're fit and forget (hopefully) but the Audi RS4 rear calipers I cheap needed new seals so I set to with rebuilding the calipers

[img] http://i690.photobucket.com/albums/vv264/performanceghia/IMAG0750.jpg [/img]

I worked the handbrake lever and pulled the piston out.

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You can see the screw/bolt which pushes the piston when you activate the handbrake.
The piston size is 42.6mm and they're in good condition with no corrosion.

A quick polish, new seals and a squirt of brake fluid and they are going back together.

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Two rear calipers with new seals ready to fit. You have to rotate the pistons clockwise in order to push them in.

The Audi RS4 uses M12 X 1 mm banjo fittings but they also have a rear brake pipe which had both hard line and flexi in one. As such you can't use that on your conversion. I took a caliper into my local GSF and they allowed me to search through their shelves of VW/Audi brake flexi pipes. I found some which came on the back of a 2000 VW Passat.

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They come with the banjo bolt and washers built in.

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All ready to fit. I just need some more time...

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MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

rubbachicken · Posted: Sun Sep 25, 2011 5:32 pm Post subject:

SyncroGhia · Posted: Sun Sep 25, 2011 11:41 pm Post subject:

Thanks, I agree that the pop top looks much much better but with our needs, form has to come second to function in this matter.

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

offroad. · Posted: Mon Sep 26, 2011 3:56 am Post subject:

mike i`ve been going through the same dilemma. a high top would better suit our needs as a family i`m sure. but i`ve since bought a kayak and carrying all the stuff on the roof i am now wondering if i could fit everything on the high top. back to the undecided stage again.

dont know whether i`m loving the red cream combo yet.

lee

SyncroGhia · Posted: Mon Sep 26, 2011 4:02 am Post subject:

SyncroGhia · Posted: Wed Sep 28, 2011 6:55 am Post subject:

Rear brake update..

I finally managed to grab some time last night to get started on the rear brakes.

Starting point...

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Stock Syncro 16 rear brakes...

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Stock Syncro 16 rear hub...

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Comparrison of Syncro 16 and 2WD/Syncro 14 rear hub

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Hub removed...

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Stuff removed

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Stuff going back on

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A quick clean of the threads

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Hub and caliper bracket fitted

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Carrier and disc fitted

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Caliper fitted... but there is a problem

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Fitting the caliper in this position has the handbrake mechanism hitting the rear spring. Also the hydraulic pipe isn't happy either.

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Ok change of mind, I pulled everything off and bolted it back on at the back instead.

As a result, I need longer handbrake cables from Futbus and Dave is sending them out to me pronto. Until then... it sits in gear on the drive!!

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MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Wed Sep 28, 2011 2:25 pm Post subject:

Just info of the parts I've used for the rear disc conversion.

The reason for going with these specific parts is that they'll fit inside stock Syncro 16 steel wheels and use vented brake discs.

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Diameter is 278mm give or take...

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Disc thickness is 22mm.

I can't remember atm what they're from but Mercedes front brake discs sound about right. Annoyingley I seem to have thrown the box away!

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The reason for the photo of the pads is that on the RS4, the braking efficiency comes from having much bigger diameter brake discs inside 18inch wheels but with small (depth) brake pads. I wanted as big a brake pad as I could get into the caliper carrier so I went looking and found that these pads are around 8mm deeper that stock so you get more surface area = more braking.

It also means I have a record for when I need to change them in the future as my memory is crap Very Happy

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Fri Sep 30, 2011 12:25 am Post subject:

Some goodies have arrived from Futbus Smile

The longer handbrake cables and a pair of bigger spring spacers. If the spacers look different, that's because they are.

One 30mm and one 40mm spacer. This may sound odd but with all the cabinets on one side in the Westfalia interior, I've been running an extra 10mm spacer up front and an extra 20mm spacer at the back since I've fitted the interior to get the van to sit level. This way, I don't have 2 spacers on top of each other.

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I've been meaning to replace the current setup for a while as the 10mm spacer has developed a crack and the front springs have settled. As such, it's dropped in height. I also get to fit the Syncro 16 front shocks back on as I used a set of Syncro 14 shocks with the Beetle shocker lengthening pins. Now that I've been running them for over a year without problems, I'm happy enough to do the same to the 16 shocks.

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Fri Sep 30, 2011 4:40 am Post subject:

Handbrake cables all fitted and pinned up out of the way.

I'll keep an eye on them when offroading.

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Thanks to Futbus for being so quick to get these to me at short notice.

Now it's on with the roof.

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

westyventures · Posted: Fri Sep 30, 2011 7:53 am Post subject:

Have you seen what Derek (or was it Ecic?) did on his van? Tubes inside the trailing arms to route the cables through for complete protection.
_________________
Karl Mullendore
www.westyventures.com
www.propexusa.com
Propex Heatsource US-HQ and Truckfridge sales and installation - We give you the best options to keep your warm things warm and cold things cold!

SyncroGhia · Posted: Fri Sep 30, 2011 8:22 am Post subject:

rubbachicken · Posted: Fri Sep 30, 2011 12:20 pm Post subject:

Zeitgeist 13 · Posted: Fri Sep 30, 2011 12:37 pm Post subject:

See his sig ^
_________________
--Casey
'89 Bluestar
"Endeavor to persevere"

axeman · Posted: Fri Sep 30, 2011 1:50 pm Post subject:

have you used the 14inch or 16ins bearing carriers for your conversion? looks like a good set up?

neil
_________________
1957, 1200cc 30hp, big window, delux beetle, swedish modle, now living in france
1991 holdsworth villa 3, 2.1, uk van, now sold
1991 syncro doka 2.1 uk van
1987 syncro westy 1.6 jx

SyncroGhia · Posted: Fri Sep 30, 2011 2:57 pm Post subject:

Hi Neil, I've used 2WD\Syncro 14 hubs so I don't limit parts availability.

On with the front suspension.

I went to the local GSF and bought 2 Beetle front shock absorber fitting kits, all of £6.75 each! And set about fitting them to my Syncro 16 front shocks.

When I did this last time, I re-threaded the shocker pin from M10 X 1.0 to M10 X 1.5 and removed the small top section with flats on. This time I wanted to try to fit the without modifying the shock absorbers so I rethreaded the Beetle part to M10 X 1.0. I also looked at how the pin (with fittings) locates into the body.

On the stock setup, the top of the bump stop has a metal insert and is then coated in rubber. This keeps the pin central. On the Beetle part, this part is unshielded steel.

Looking at the parts carefully, I realised that this metal disc on the Beetle part is only pressed on so off it came. I chopped off the bump stop part and kept the location part of the T3 fitting, drilled this out just enough for it to fit onto the Beetle part.

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This is how you get the Beetle part.

Remove these parts

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And rethread to M10 X 1.0

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One stock shocker all cleaned up

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Knock the metal disc off the Beetle part.. and cut the locating part off from the T3 bump stop and you should have these parts.

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Drill out the metal insert in the T3 part to around 15mm so that the Beetle part will pass through it and sit on the next step of the shaft. You'll have to do this in a vice as the rubber is tough and doesn't want to accept the next section which is almost 20mm.

Check that It screws on ok...

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Fit the another complete bump stop as per normal - keeping the factory bump stop action and length and tighten up.

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And it should look something like this.

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The Beetle part lengthens your stock pin by 51mm but keeps your stock bump stop length and shock absorber action length.

You will need a multitude of other mods to be able to make the most of this one properly so don't expect to just do this and it be great. I'm just upgrading to 30/40mm spacers with these so it's fairly high.

One side done and fitted... I'll do the other side tomorrow.

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MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Sat Oct 01, 2011 1:45 am Post subject:

All done and back on it's wheels.

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I think I need to jack the back up again...

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As we are all modifying our arches and Limey's are... Well... Less that perfect Wink

, I'm taking measurements from the roof gutters to the wheel centre and not pulling the tape in to get to the wheel centre for accuracy.

NSF is 1620mm, OSF 1623mm.

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

SyncroGhia · Posted: Sat Oct 01, 2011 1:56 pm Post subject:

A quick jacking up of the rear with some more spacers and it now sits like this...

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Heights for the rear are:

OSR 1632mm, NSR 1635mm from the gutter to the wheel centre.

MG
_________________
1989 Syncro 16 S6 Westy Limey
1991 Syncro Lightweight SWB
1989 S8 Bluestar
1990 Tristar

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Limey, The Syncro 16 Westy. Was 2.5TDi, Now 2.2 20V Turbo!
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