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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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 Posted: Wed Feb 03, 2016 2:28 am Post subject: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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The day has come! For a while now, I have felt a slight moral obligation to give back to this community for all of the knowledge that I have gained here. Since, I am not technically savvy, the only thing I can really do is post my Syncro story of ups and downs and document the build so that some may find enjoyment while others can learn form my mistakes. The hope from the beginning was to have a safe and reliable daily driver to haul the family around in all 4 seasons, with the added versatility of being able to take us to scenic landscapes, far from the relentless and daily grind of the rat race.
A bit more of the narrative: I spent 6 months researching my options for my next family car. The inclusion criteria were that it had to be 1) all-wheel drive, 2) be able to comfortably sit at least 6, 3) meet my budget in the teens, and 4) be something that I could enjoy driving. Exclusion criteria - please no mini-vans.
I seriously considered the following:
The was def. a possibility
and so was this
hmmm, pass.
 Only if this were an option!!!
ACT 1 The set-up
I came across the syncro because of the "AWD, van" google searches but it just wasn't a realistic option. That is until I came across a seemingly-random craigslist add for this engine-less, 86 syncro tin-top that was located 5 hours West of me.
No locker. No title. No engine. I didn't really know to ask about rust. Unknown condition of tranny..... Ignorance is bliss!! At 4 grand, it was the right one for me. Plus carfax confirmed that it was last registered in 2000 in VA at 70k miles and history was otherwise clean. My second car was a 1990 VW corrado G60 with a turbo conversion, so the thought of owning VW van brought on feelings of nostalgia
In Feb, 2015 I set out to pick it up. Little that I know that a year later I would still be waiting for my first drive ever in a vanagon:
As many know, the scope of the purchase cannot be assessed until the day after, when all of the adrenaline wears off. Here are some of the morning-after pics of the problem areas
All in all, it turned out to be a treasure (so I thought).
ACT 2
The confrontation
So the car sat around for months while I read through the samba endlessly. The topics of interest were mainly the engine conversion but all other mechanical restoration was also on my mind.
I decided on a Subaru EJ25 because it best suited my needs and wants, with the Rocky Mountain Westy conversion kit.
I found a side impact 2004 Subaru Impreza RS with 60k miles and a clean carfax from Central Auto Recycling in Syracuse NY. They made sure to get everything on my list including the entire harness from the same car and replaced the belts and gaskets for about 2k - Thank you very much!
Ultimately I had no choice but to outsource the build given that I absolutely have no spare time. Besides, it would have taken me at least 3 times longer than projected given my limited experience. Trustoworthy Syncro mechanics are hard to come by in my area but there are a few. I reached out to Vanaru and InSyncro but ultimately (and for many competing reasons) I did the most logical thing: I responded to this add in craigslist.
M.... AUTO REPAIR [HOME]
I HAVE OVER 30 YEARS EXPERIENCE ON FOREIGN & DOMESTIC CARS & TRUCKS. I WORK OUT OF MY HOME . . I AM A SKILLED PROFESSIONAL I HAVE ALL TOOLS & EQUIPMENT NECESSARY TO PERFORM ALL JOBS. BRAKES, FRONT END WORK, SHOCKS, STRUTS, TUNE-UPS, TIMING BELTS, (SPECIAL) WATER PUMPS, ALTERNATORS, STARTERS, BATTERIES, ENGINES, TRANSMISSIONS, CHECK ENGINE LIGHTS, DIAGNOSTIC WORK, TROUBLESHOOTING, ELECTRICAL WORK, ETC. I PROVIDE A FREE PICKUP & DELIVERY SERVICE. ALL WORK IS GUARANTEED FOR 1 YEAR, PARTS & LABOR. REFERENCES AVAILABLE. LET ME BE YOUR PERSONAL MECHANIC. I AM HONEST, FAIR & PROFESSIONAL. ALSO I AM A CERTIFIED VW TECH, SUBARU TECH & AUDI TECH. MY LABOR RATE IS $65.00 AN HOUR. PLEASE CALL M.... AT
Absolutely perfect!!!!!! A VW and Subaru specialist who works from home and can do it all. What can go wrong?
I dropped off the car in April, 2015
And went on vacation to Italy
Style points
October 2015 rolled around and it was getting harder and harder to contact my "mechanic" - as most already foresaw, this plan wasn't going as well as initially conceived. I was getting the run around so I made the hour drive to discover the following (sad background music please  )
ouch
ACT 3
Resolution
I don't really like to talk about it, but in retrospect, it had an obvious lapse in judgment and as a result my car was in pieces. I was also deeply invested in it emotionally and materially so I need to figure something out.
It was then that I finally stumbled on Andrew Flint's Quattro Syncro, reverse running 1.8t, 5 speed project (http://www.thesamba.com/vw/forum/viewtopic.php?t=568346) and realized that he is about 2 hours north of me. He was willing to take on the mechanical aspect of the conversion mostly because I think he pitied what had been done to the van.
In Oct. 2015 I managed to tow it for the third and hopefully last time to Andrew at Flint European Auto. It's bad when the people at Uhaul know exactly what you need.
On my way there I saw this, a sign that things were looking up perhaps.
And here we are - Flint's vanagon hospital
Work started in mid December 2015 with
Engine prep
Feedback from Andrew has been that RMW parts are extremely well made.
Transaxle Prep
Thanks to InSyncro for some hard to find syncro transmission mounts - delivered within a day of the transaction and the Westyventures starter adapter.
The tank
Cooling
Brakes, hubs and studs
Thanks to T3 Technique for the valued support and quality parts
Some body re-enforcement from RMW
Again, I have heard nothing but praise for the RMW parts including these bumpers that seem to fit perfectly.
The front
The rear
Engine drop
The mechanical build is still being done by Andrew Flint and the pictures above were provided by him. The excellent workmanship is obvious and the pictures speak for themselves.
Now that we are all up to speed and the build is live.... I look forward to seeing and posting the latest developments.
All4Him |
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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Wed Feb 03, 2016 9:05 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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I have seen this van a few times now while under construction.
A very nice Syncro.
Andrew does great work.
It will be even sweeter when completed.
Last edited by insyncro on Wed Feb 03, 2016 11:57 am; edited 1 time in total |
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WestyBob
Samba Member
Joined: June 11, 2004
Posts: 2346
Location: Portland, Oregon
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| Posted: Wed Feb 03, 2016 10:54 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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A wonderful documentary and probable successful conclusion after that burp with the scoundrel. Keep it coming.
And I hope that scoundrel will not be allowed to bushwhack the next unsuspecting innocent. |
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SyncroChrick
Samba Member
Joined: January 10, 2005
Posts: 1010
Location: San Francisco, CA
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| Posted: Wed Feb 03, 2016 11:21 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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You misadventure with Craigslist is unfortunately way too common but that picture is priceless...
I am glad to see that you found a better option and looking forward to the rest of the build. I am myself restoring a 1989 Syncro. I just replaced the engine and I am now attacking every other component on the van. You are going at it the correct way by doing everything at once. Those vans are so old by now that the only real way of getting a reliable vehicle is to inspect/replace/fix every part.
When I have time later I will post pictures and a complete list of things I have had to fix - it is quite endless... |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16502
Location: Brookeville, MD
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xoo00oox
Samba Member
Joined: February 11, 2010
Posts: 2672
Location: East Nassau, NY
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| Posted: Fri Feb 05, 2016 4:43 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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I was very happy to turn the key for the first time and hear the 2.5 come to life today!
This van is very nice to work on. It has never been molested, has very low miles, and has very very little rust. Charles is a great guy to deal with as well, always quick to reply to anything and understanding of how old cars are to deal with.
Ive been very happy with parts sent to me from Rocky Mountain, GoWesty, T3 Techniques, and InSyncro for this build.
While the Subaru 2.5 is not really what we are usually doing at this shop these days, this job reminds me of what a nice fit it is in these vans. 165 normally aspirated horse power and better MPGs that the stock engine along with a very nice smooth power band, it is a very good choice! |
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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Fri Feb 05, 2016 5:12 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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Nice!
Was planning to see you this coming week.
Can't wait to see and hear it. |
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Fri Feb 05, 2016 7:54 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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Don't have to wait much longer!!!! 
Link
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16CVs 
Samba Member
Joined: February 22, 2004
Posts: 4024
Location: Redwood City, California
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| Posted: Fri Feb 05, 2016 8:38 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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When I first saw this thread open up and your location, my first thought was dump the Subaru and put a 1.8 with one of Andrews Audi Set ups.
Andrew Flint is the man in your area who will just get it done. Welcome to the madness.
Stacy
_________________
1987 Syncro Westfalia Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread. |
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Fri Feb 05, 2016 8:59 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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| WestyBob wrote: |
| And I hope that scoundrel will not be allowed to bushwhack the next unsuspecting innocent. |
I honestly blame myself because even though I saw it coming, I still walked right into that fowler's snare. I'm really happy to have come out of it, given that I almost lost hope when I saw it in pieces. Andrew did however have to go through the entire front end after what had been done to it. It was ugly and downright dangerous.
Thanks for the support dobryan and SyncroChrick. I think it would be helpful to log the list of parts along with the mods for the build. It's extensive - absolute madness indeed.
Stacy, I definitely thought about the 1.8t but was far too invested in the Subaru to change the plan. It sounds like a symphony to me. Its in great hands. |
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rmcd
Samba Member
Joined: October 29, 2010
Posts: 1348
Location: PNW - its a dry rain.
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| Posted: Sat Feb 06, 2016 11:36 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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| All4You wrote: |
| WestyBob wrote: |
| And I hope that scoundrel will not be allowed to bushwhack the next unsuspecting innocent. |
I honestly blame myself because even though I saw it coming, I still walked right into that fowler's snare. I'm really happy to have come out of it, given that I almost lost hope when I saw it in pieces. Andrew did however have to go through the entire front end after what had been done to it. It was ugly and downright dangerous.
Thanks for the support dobryan and SyncroChrick. I think it would be helpful to log the list of parts along with the mods for the build. It's extensive - absolute madness indeed.
Stacy, I definitely thought about the 1.8t but was far too invested in the Subaru to change the plan. It sounds like a symphony to me. Its in great hands. |
Thanks for taking the risk to share!
Don't beat yourself up too much. Sometimes shit happens with custom projects that isn't anyone's fault and sometimes shop staff are not well vetted and some shops just shouldn't be in "business"! I've survived two custom builds with two vehicles with four high profile professional shops with way more than 50+ years of experience between them.
Double J motorwerks was awesome.
Question. What is the goo on the fuel sender plate?
_________________
VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight= |
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xoo00oox
Samba Member
Joined: February 11, 2010
Posts: 2672
Location: East Nassau, NY
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| Posted: Sat Feb 06, 2016 12:38 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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| fluid film is on the fuel tank sending unit to keep rust and corrosion away. |
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BavarianWrench
Samba Member
Joined: January 18, 2004
Posts: 1045
Location: Oceans Edge
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| Posted: Sat Feb 06, 2016 12:42 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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| Enjoy that Syncro, it is always a long road to a good rig. Yours is looking sweet. I like seeing Flint posts. He is a rare one. I hope to meet him someday, very innovative guy! |
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Sun Feb 07, 2016 3:04 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restora |
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| BavarianWrench wrote: |
| Enjoy that Syncro, it is always a long road to a good rig. Yours is looking sweet. I like seeing Flint posts. He is a rare one. I hope to meet him someday, very innovative guy! |
Thanks. My excitement is tamed by he thought of having to restore the interior before I feel settled. Additionally, the body - especially around the windows - needs some work but I simply don't know if I will be able to address that now. It's obvious that I've been bitten by the restoration bug (always thinking about what's next rather than enjoying it as is)
By the way, I was perusing your pics and love the bimmer and hightop. Part of your fleet?
All4Him |
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Fri Feb 19, 2016 7:50 pm Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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When I bought the van I was told that the transaxle may have been rebuilt two owners back, in preparation for a turbo conversion. As much as I wanted to believe it, I was skeptical and so was the seller. While prepping the trans Andrew found this hiding out in the oil
He thinks it's the 3-4 synchronized hub.
Not good news obviously but gives me a reason to upgrade to a locker. I can also now speculate as to why it was last registered in 2000.
All4Him |
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xoo00oox
Samba Member
Joined: February 11, 2010
Posts: 2672
Location: East Nassau, NY
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| Posted: Sat Feb 20, 2016 7:13 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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Yes, this was defiantly a blow. Sure looks like the 3-4 slider keys to me. Everything else had been going pretty smooth until this.
On a lighter note...
A funny thing happened while working on this van. Since getting it back together, I noticed the key was kind of hard to get to turn. I had to jiggle it in the lock cylinders to get it to work. I thought it was strange because the low miles on the van and the key didn't look worn out much.
I realized yesterday that I had been using the key to someone else's car. It just so happened to be close enough to that it would work. |
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Sat Feb 20, 2016 7:39 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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Hehe
That doesn't bode well for my already lacking security system. Especially now that it's posted on the Internet. 
Good thing is that only a fool (or very rare enthusiast) would find these rolling boxes attractive and worthy the risk of going to jail for. |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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All4You
Samba Member
Joined: March 01, 2015
Posts: 146
Location: NY
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| Posted: Sat Feb 20, 2016 7:53 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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| Thanks Dave. I rather that over the current high tech keys. Especially if I'm in the middle of nowhere or even a town without a VW dealer. |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32586
Location: Reading Pennsylvania
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| Posted: Sat Feb 20, 2016 8:10 am Post subject: Re: 86 VW Syncro, Subaru EJ25 conversion, mechanical restoration |
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That's quite a journey you've been on but it looks great!
You know what they say...... What doesn't kill you makes you stronger.
FWIW...... Your rust......
If you can't get to your rust right now, resist the urge to soak it with anti rust penetrants. They often contain compounds that are tough to fully remove when you are finally ready for a proper repair.
You would be well served to scrape away the rust,
treat with a rust treating paint of your choosing.... POR 15 or similar,
caulk over the rust paint with a auto body seam sealer, paint the seam sealer to match the body color,
run a bead of NON HARDENING windshield bedding compound to prevent further water intrusion around the glass,
and finally......
call it good until body work day comes around.
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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