Syncro Doka Hybrid Dream Build

[WestyandaSprinter]

I finally found my dream doka! 1985 Syncro Doka. Here's the catch: the Syncro transmission and front diff were sold separately a while back. Pretty common issue a lot of us have run into. The front syncro subframe is all intact--just minus the differential.

I was able to get a package deal with this doka for a running 2.1L engine and 2WD manual transmission. Here's the plan: Get it running as a stock 2WD asap. Drive it around and have fun.

Now, I want to have FWD capabilities as well. I don't want to fork out all the money to source a syncro transmission, drive shaft, and diff.

SO, I am going to do something weird. Front wheels will be powered by an electric motor. I know I am not the first to think of this. Gowesty and Bostig have done similar things. Gowesty most notably in the Norra 500 race series.

The most appealing thing about this setup would be that I could have completely independent front and rear drive systems that communicate with one another. If one fails (most likely the 2.1L engine), I can use the second drive system to get me home--or out of danger.

I plan on buying a wrecked Zero motorcycle for under $2000. This way I will get all the major components for an EV system that for sure work together. Even the battery! The Zero SR motor has a peak power of 67 HP. Not great but not bad. I will adapt the electric motor to mount directly to the front diff. I don't really want to use a stock syncro front diff because they are expensive and could be better used for someone doing a stock conversion. I've heard rumblings of the Audi 5000 rear diff working if you flip it upside down... is this true? I could use almost any diff as long as it fits into the front subframe and then get custom CV axles made.

Any thoughts on this? Worth trying? For reference, I convert vintage Vespas to electric so I am familiar with the EV conversion process albeit on a smaller scale with a lower voltage (72v). I am also familiar with the negative responses EV conversions often get from the purists! SO, if you are anti EV, remember, I am keeping the rear of this doka stock as a block

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[WestyandaSprinter]

Here she is

[Sodo]

That sounds like fun!

If you find someone who replaced the WBX & trans for a Subaru & 5MT you have it all. 67HP to help get up the hills is a lot of assistance.

I don't understand how the electric and gas motor can work together at steady-state.

In "assist" like uphill, or regen/braking, yeah I can see how that would work, but how to get it to integrate automatically is way beyond my understanding.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[mitch5]

[MsTaboo]

Something odd going on here, I've never seen a Syncro Doka with the fuel filler in that location.
Are you sure was a real Syncro? Maybe post the VIN (with the last three numbers blanked out if you're worried about security).

Hope your plans work out for a hybrid electrical setup!
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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.

[vwhammer]

Not trying to be Debbie downer here but that zero motor will probably not last long trying to move a full-sized vehicle around.

A full-sized vehicle would be quite a load for a motor that small and, given that the zeros are air-cooled, it would likely overheat in short order.

You will either need a larger motor or a very well-sorted liquid cooling setup on a smaller motor to survive in that type of situation.
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Pretty normal daily driver build
https://www.thesamba.com/vw/forum/viewtopic.php?t=708418&highlight=

4x4 build
https://www.expeditionportal.com/forum/threads/volkswagen-vanagon-4x4-conversion.162055/

[Sodo]

Interesting about the fuel filler etc.
Do the front spindles have CV flanges inside?

[WestyandaSprinter]

[ALIKA T3]

It wasn`t a mistake per se, the guy who converted it prolly didn`t have a pick up tank and used a Van tank and put the filler in the back
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[16CVs]

I think a VIN would be a great starting point.

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.

[MsTaboo]

[WestyandaSprinter]

My doka arrived! I have named her Sheila.

Time to get to work. Step one, get the transmission installed. So, as mentioned before, this doka was converted to a syncro at some point in time. Meaning that some things have been cut/welded/brackets added. First thing I found was that two brackets were welded over the transmission front mounting holes. Easy enough, time to break out the grinder. 20 minutes later and 1 exploded grinder wheel in my face, the mounts are removed.

Here's my question: which set of mounting holes do I use for my transmission mount!? I've searched the forum and haven't found a definitive answer. I believe I have an early manual transmission (picture attached). Any input?


P.S. the pics of the welded brackets removed is part way through the removal process, its cleaner and painted over now!

[WestyandaSprinter]

Asking again,

Which set of mounting holes do I use for my transmission mount!? I've searched the forum and haven't found a definitive answer.

Planning on installing the transmission on Wednesday and would like to do it right the first time! Cheers

[dobryan]

[ALIKA T3]

[4Gears4Tires]

[WestyandaSprinter]

[WestyandaSprinter]

Week 1 of progress on the Doka project.

Here's what I accomplished.

1. I printed out diragrams of all major systems (brake, coolant, fuel lines, wiring, etc.) and marked them with all the parts I currently have. Everything missing/needing to be replaced was highlighted and ordered.

2. CLEANED. This doka was dirty. Spent a few hours cleaning. Removed all the rubber floor mats. Suprisingly rust free! Pulled out the rear set heater tunnel thing. Never seen one of these before. Pretty cool. Removed front seats for my stow and go swap.

3. Brainstrormed. Thought more about the Electric front drive unit. Watched some Bostig/Small car/Gowesty videos on their electric stuff. Definitely doable.

Here are my questions for all you Vanagon Gurus out there:

A. My transmission was rebuilt and then installed in a vanagon. The garage the vanagon was in burnt down and so did the van. The transmission was pulled and sold to me. The clutch slave cylinder is toast as are the tranaxle side screw locks (plastic retainer on each side). What else should I replace? All the other rubber seals on the transmission feel fine and aren't leaking.

B. As mentioned above, I have a 30 gallon aluminum fuel cell I will be using for the gas tank. It will be sitting in the treasure chest area. Should I use stock vanagon fuel pumps and filters? Or should I just get a standard fuel pump/filter/level sensor combo kit?


Next Week: Stow and Go seat install! I got these seats a couple months back for $70... for BOTH. I have used them in my T1N Dodge sprinter van since. Now they will make the promotion (or demotion!?) to the Doka.

Pic of the syncro subframe missing the front diff:

Pic of aluminum spacers/adapters to fit subaru wheels and tires:

[pkrboo]

Why not use the syncro fuel tank and save the tresaure chest for batteries? or has it already been removed?

I have been thinking of doing somehting simlar, i have converted the backend to syncro with fuek tank etc and am on the look out for a front end but use an electric motor like you plan to.
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1979 Sage Green Westfalia P22

[WestyandaSprinter]

Lots of good points made by viewers of this thread. I've been tinkering away on this 1 night per week as it's stored in a driveway I can only go to once per week

That means I have a lot of time to think about everything...a lot more time than I have actually spent tinkering on it.

I am toying around with going with a full EV conversion--AWD all the time using tesla motors. They're becoming increasing less expensive as more and more of them get crashed by people texting while driving and trusting the "self driving" feature.

If I go this route, I would sell the stock 2.1 sycnro set up waterboxer and rebuilt manual transmission (less than 150 miles on the transmission).

What would this stock set up be worth if I sold it as a package deal? Running motor (gowesty exhaust) and rebuilt manual transmission. I paid 1500 for each--so 3k total. Do you think I could get that $$ back by selling?

TIA