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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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 Posted: Tue Sep 02, 2014 10:00 am Post subject: |
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| insyncro wrote: |
Signal,
Is this a plated, stock, header or and aftermarket one?
Building up two Zetecs currently for conversions and was curious.
TIA. |
It is the factory header that I had Jet-Hot coated (http://www.jet-hot.com/). I saw a couple of aftermarket versions, but I do not believe there really is any room for improvement and wasn't sure how/if it would affect the tune. |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Fri Sep 05, 2014 2:45 pm Post subject: |
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So the moment finally arrived … with the help of a couple of co-workers/friends, final prep of the engine for install commenced. The transaxle mated up evenly with the engine, only needing a couple of shimmies for it to slide into place. I would like to comment once again on the quality of design and fabrication on the Bostig specific parts, as everything went together perfectly. The clutch is a factory Sachs unit from Van Café, and I included the GoWesty gear reduction starter as well. I used a couple of floor dollies with some metal shelves bolted together to provide a platform for the mated engine and transaxle, allowing me to position it nicely under the van. There were a lot of long hours getting to this point, I had to stand back and soak it all in for a moment lol. It seemed forever ago, when I removed the original drive line.
TIP:
The instructions for the GoWesty starter state to clock the mounting flange, when installing in a Syncro (to position it correctly under the gas tank). This is not possible with the Bostig conversion, as there is no way to get the bolt past the starter body. It would run through from the engine side on a factory setup. I was able to leave it “as is” due to the fact that I left the insulation off of the gas tank. This allowed the gas tank to sit up a bit higher, and afford more room above the starter as well. If the insulation was still in place, there is a chance it might have interfered.
Last edited by Signalocity on Mon Sep 08, 2014 6:57 am; edited 1 time in total |
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Farfrumwork
Samba Member
Joined: October 10, 2008
Posts: 692
Location: Mile High
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| Posted: Fri Sep 05, 2014 3:02 pm Post subject: |
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I guess that's ok... IF you like spotless drivetrains (and under-carriages) 
Still in  over this van
(I use a skateboard in conjunction with an engine hoist to move my motor/tranny in & out...  )
_________________
sold  -> '85 Wolfsburg Syncro / 'Built' DOHC EJ25 (a great machine!)
'07 Legacy spec.B, road tuned stgII
'17 4x4 Sprinter, stone grey, SMB pop-top, on 33"s
"Blood stains, speed kills - Fast cars, cheap thrills - Rich girls, fine wine - I've lost my sense, I've lost control, I've lost my mind" |
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bostig
Samba Member
Joined: February 01, 2006
Posts: 235
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| Posted: Fri Sep 05, 2014 6:09 pm Post subject: |
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You could eat off of it... NEVER drive that van to the east coast one winter and it would all be for naught!
Note on the GW starter, pull it again and file the top tooth chamfer to match the OE starter pinion gear, the GW one is bidirectional, it'll work better on the brand new ring gear teeth that way.
Nice!
Jim Akiba |
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luVWagn
Samba Member
Joined: February 21, 2008
Posts: 1340
Location: Snoqualmie (WA)
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| Posted: Fri Sep 05, 2014 8:06 pm Post subject: |
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That's a whack of capacity on the networking rack?!!!
Oh and yeah, I want to hire you for a syncro 16 restoration - but probably can't afford it :p
_________________
'91 Syncro 16 Reimo Hightop Conversion, eTDI |
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JudoJeff
Samba Member
Joined: May 24, 2013
Posts: 1179
Location: Near Springfield, MA
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| Posted: Sun Sep 07, 2014 8:18 am Post subject: |
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You're the Gold Standard for Syncro conversions and rebuild! Most impressed!
_________________
________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout) |
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tjet 
Samba Member
Joined: June 10, 2014
Posts: 3533
Location: CA & NM
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Mon Sep 08, 2014 7:28 am Post subject: |
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| Farfrumwork wrote: |
| (I use a skateboard in conjunction with an engine hoist to move my motor/tranny in & out... ) |
Loving the skateboard idea! |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Mon Sep 08, 2014 7:36 am Post subject: |
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| bostig wrote: |
You could eat off of it... NEVER drive that van to the east coast one winter and it would all be for naught!
Note on the GW starter, pull it again and file the top tooth chamfer to match the OE starter pinion gear, the GW one is bidirectional, it'll work better on the brand new ring gear teeth that way.
Nice!
Jim Akiba |
But I live on the east coast! ... just not in the rust bubble part lol. Thanks on the starter tip, I will put that on the to-do list. |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Mon Sep 08, 2014 7:56 am Post subject: |
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| JudoJeff wrote: |
| You're the Gold Standard for Syncro conversions and rebuild! Most impressed! |
Engine conversion? This van was born a Syncro I appreciate it! |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Mon Sep 08, 2014 8:05 am Post subject: |
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I wasn't planning on it. The header is going to be much hotter than the muffler, and I am not thinking there would be much benefit to restricting the airflow to the upper part of the exhaust. I do have the stainless header shield from Bostig though. Thanks! |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Mon Sep 08, 2014 8:13 am Post subject: |
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| luVWagn wrote: |
That's a whack of capacity on the networking rack?!!!
Oh and yeah, I want to hire you for a syncro 16 restoration - but probably can't afford it :p |
Stop staring at my rack!
Paying me is one thing, talking me into it is another.  |
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MsTaboo
Samba Member
Joined: June 02, 2006
Posts: 4098
Location: East Kootenay, British Columbia
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| Posted: Mon Sep 08, 2014 9:36 am Post subject: |
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| Signalocity wrote: |
I wasn't planning on it. The header is going to be much hotter than the muffler, and I am not thinking there would be much benefit to restricting the airflow to the upper part of the exhaust. I do have the stainless header shield from Bostig though. Thanks! |
That photo is of my engine compartment before it was completely finished. I actually did fashion a small shield out of leftover Wasserboxer engine tin that shields the coolant hose from the muffler. The hose isn't as close to the muffler as the photo makes it seem (perspective) but I did feel some shielding would help, although it's really not very big, about 4"x10".
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec
The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
Help the fight against Truth Decay.
Defend democracy, support Ukraine. |
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tjet
Samba Member
Joined: June 10, 2014
Posts: 3533
Location: CA & NM
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| Posted: Mon Sep 08, 2014 1:16 pm Post subject: |
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| Signalocity wrote: |
The header is going to be much hotter than the muffler, and I am not thinking there would be much benefit to restricting the airflow to the upper part of the exhaust. I do have the stainless header shield from Bostig though. Thanks! |
You will like that Zetec engine. I got to drive one last weekend. Felt like a new car, & we had the a/c on ice cold too
I'm going to drop my eng/trans this week in my 87 Syncro. I've decided to go after the fuel tank at this time. The sender is kaput, but I'm mainly concerned about the condition of the fuel lines. I'm also going to try to clean up the eng compartment/ trans tunnel area.
Did you reuse the original heat shield/insulation on your tank? I'm trying to find one of those.... |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Tue Sep 09, 2014 6:07 am Post subject: |
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| MsTaboo wrote: |
| That photo is of my engine compartment before it was completely finished. I actually did fashion a small shield out of leftover Wasserboxer engine tin that shields the coolant hose from the muffler. The hose isn't as close to the muffler as the photo makes it seem (perspective) but I did feel some shielding would help, although it's really not very big, about 4"x10". |
I will keep an eye on it and revisit later if need be. Good to know though! |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Tue Sep 09, 2014 6:15 am Post subject: |
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| tjet wrote: |
| Signalocity wrote: |
The header is going to be much hotter than the muffler, and I am not thinking there would be much benefit to restricting the airflow to the upper part of the exhaust. I do have the stainless header shield from Bostig though. Thanks! |
You will like that Zetec engine. I got to drive one last weekend. Felt like a new car, & we had the a/c on ice cold too
I'm going to drop my eng/trans this week in my 87 Syncro. I've decided to go after the fuel tank at this time. The sender is kaput, but I'm mainly concerned about the condition of the fuel lines. I'm also going to try to clean up the eng compartment/ trans tunnel area.
Did you reuse the original heat shield/insulation on your tank? I'm trying to find one of those.... |
I have been very happy with the progression of things so far and I do have an A/C setup in mind, but that is a ways down the road.
Regarding the fuel tank, about halfway down the page ...
http://www.thesamba.com/vw/forum/viewtopic.php?t=5...p;start=40
Cheers! |
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Signalocity
Samba Member
Joined: February 13, 2012
Posts: 573
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| Posted: Thu Sep 11, 2014 10:31 am Post subject: |
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Nothing too noteworthy on the engine install, just took my time so as not to clip anything. I then began the process of making connections and routing hoses/lines. One benefit mentioned by others on numerous occasions, is the Bostig harness. All of the electrical connections terminate right where they need to be, no fuss.
TIP:
Before final torque on the engine cradle to frame bolts, take some time and make sure you stay centered between the shocks. Mine wanted to wander over to the passenger side as I tightened everything down.
TIP:
On the engine cradle lock down bolt (picture number 9), you need to drill the hole. Verify that you are not drilling into, or behind, the vertical part of the frame rail and leave enough space for the washer as well. My first instinct was to center the bolt in the slotted hole in the cradle … until I thought to stick my finger in there to check lol. I didn’t make this mistake, but I almost did.
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wasserbox
Samba Member
Joined: April 08, 2008
Posts: 533
Location: Durango, CO
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| Posted: Thu Sep 11, 2014 11:01 am Post subject: |
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| Quote: |
| Stop staring at my rack! |
I think you need another uplink on your secondary supervisor if you really want to have full redundancy
 |
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MsTaboo
Samba Member
Joined: June 02, 2006
Posts: 4098
Location: East Kootenay, British Columbia
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| Posted: Thu Sep 11, 2014 11:41 am Post subject: |
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Interesting that you have the old CNC intake elbow. I bought one of those a year or two back to replace the original 90* steel pipe intake thinking it would be better. It isn't!
Do yourself a favor and get the new "Cobra Head" intake and do a RG3 intake setup. Ditch the hose! It will mean a new snorkel path on the drivers side, but worth it to keep the air cool.
http://i70.photobucket.com/albums/i99/JASONSHEA/IMG_8172_zps0158be73.jpg
I have a Group 6 install setup with the ECU in the rear drivers side corner and will need to figure a way to redo my wire harness, but I plan to change my intake setup to the new style. Much shorter air intake path. Until then I will buy the Cobra Head to replace the steel intake.
The new RG3 intake path is the way it should have been from the beginning, and now that Bostig has bailed on the Turbo there's no need for all that empty space on the drivers side of the engine bay.
Also, have you thought about wrapping the exhaust manifold in heat tape? It's another thing I've been contemplating to reduce excess heating of the engine lid. (even with the stainless heat shield)
p.s. Very nice work as usual!
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec
The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
Help the fight against Truth Decay.
Defend democracy, support Ukraine.
Last edited by MsTaboo on Thu Sep 11, 2014 11:50 am; edited 2 times in total |
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JudoJeff
Samba Member
Joined: May 24, 2013
Posts: 1179
Location: Near Springfield, MA
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| Posted: Thu Sep 11, 2014 11:46 am Post subject: |
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X2 re: mstaboo comment about the air intake. I reconfigured mine, very easy to do. (once you have the cobrahead...)
Much quieter, cooler air intake, no hassling with the gnarly plastic welded airbox.
_________________
________________________________________
1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout) |
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