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Wed Dec 30, 2009 2:45 pm

candyman wrote: well,
looks like i may be headed down the zetec route this winter. my question to the syncro guys with zetecs, What are you doing about your stock skid plate? will they fit with some mods? I am concerned about having my drivelline exposed

Funny you should ask this, it's what I'm spending my Christmas vacation doing :)

Yes, you can use the stock skid plate *if* you get the optional high-capacity/high-clearance oil pan (so order that if you haven't. It's very worth it, especially on a Syncro). It won't fit with the standard oil pan.

You'll need the syncro engine carrier bar (mustache bar), because that's what the skid plate bolts to. You'll have to drill new carrier mount holes on the frame rail flange about 2" back from the Waterboxer mount holes, so it'll clear the crank pulley on the Zetec. I shot for about 3/4" of room, to allow for some engine movement. Yours may differ slightly.

I strongly advise clamping the carrier bar in place while figuring everything else out, before drilling :)

Then you'll need to extend the front of the skid plate to reach the stock Syncro mount points. Square/rectangular tube stock works for this, plus some reinforcement plates at the welds.

You may need to one of the bends of the skid plate sharper, because the Zetec's cradle sits slightly lower between the wheels than the waterboxer.

You also *may* have clearance issues at the passenger side front of the HC oil pan. I did, but it was a very near thing (less than 2mm or so)on mine, so yours may differ. So you may have to solve that.

I figured all of this out and got about halfway though the mods when I discovered that my stock skid plate was a complete basket case of rust, from the inside out. Looked fine from the outside. I didn't find this until I cut it open to extend it. Sigh. Soooo, I fabricated a completely new, stronger one out of thick-walled square tubing, but kept the original mount points It looks a lot like the stock plate, but with more plate :)

Bostig is working on rock bars for the engine, but those won't cover the tranny at all, last I was told. Dunno if that's changed. TBH, I lost patience and made my own, as theirs was supposed to be done in September or so, and still aren't ready (vanishing supplier issues, apparently).

Back outside to primer the bottom,

Robyn

Wed Dec 30, 2009 2:46 pm

candyman wrote: well,
looks like i may be headed down the zetec route this winter. my question to the syncro guys with zetecs, What are you doing about your stock skid plate? will they fit with some mods? I am concerned about having my drivelline exposed

you can retain the bars that protect the driveshaft. i have a v1 conversion so the tube cradle provides some protection although i need to add a plate to it. call up the bostig guys they can tell you what will work.

Wed Dec 30, 2009 3:20 pm

[quote="squeegee_boy"] candyman wrote: well,
looks like i may be headed down the zetec route this winter. my question to the syncro guys with zetecs, What are you doing about your stock skid plate? will they fit with some mods? I am concerned about having my drivelline exposed

The driveline won't be exposed. The two rails that run along the driveline aren't changed at all. As mentioned, bostig is working on a comprehensive solution for protecting the engine - I suspect it'll be worth the wait.

Wed Dec 30, 2009 3:40 pm

awesome thanks guys!

Wed Dec 30, 2009 4:30 pm

[quote="mtnwater"] squeegee_boy wrote: candyman wrote: well,
looks like i may be headed down the zetec route this winter. my question to the syncro guys with zetecs, What are you doing about your stock skid plate? will they fit with some mods? I am concerned about having my drivelline exposed

The driveline won't be exposed. The two rails that run along the driveline aren't changed at all. As mentioned, bostig is working on a comprehensive solution for protecting the engine - I suspect it'll be worth the wait.

The engine, yes. Not the transmission, unless something's changed very recently. And yes, the stock drive shaft guards still work fine.

Edit: My Zetec was CAD$650 at a local wrecker, and I can have a new (for me) one tomorrow if I kill it. My tranny rebuild and decoupler was ~CAD$4,500 from AA Transaxle, and took a few weeks to arrange. Just so my priorities are clear :)

Robyn

Mon May 31, 2010 11:24 am

New Bostig products
It is not a great picture but you can make out a couple of new billet pieces from Bostig a over flow canister a intake manifold and one of the best engine carrier bars ever put on a vanagon. Pretty impressive clearance.

Tue Jun 01, 2010 6:43 pm

I just installed the same kit. I live in driving distance to Bostig so I went
and picked up my kit. It has all the new 2010 stuff. The same intake
adapter as you have pictured,the new thermostat housing,dual starter option,stainless custom heat shield,hc oil pan,obd extension,front Bostig tranny mount, and the new cradle.
The new cradle is like an x-wing fighter and looks very well designed. I'll tell you how friendly it is for a transmission swap tomorrow. All in all very happy with the kit. I am wishing I trimmed the "firewall" a bit before installation. I may lay a tarp over the motor and still do it.
I'd also liket o replace the Van-cafe stainless pipes I have with a custom set from Terry K this fall. i have yet to ask him but I would like the oustide diameter of the 86-91 plastic pipes . I want them to end in the engine compartment like the earlier metal pipes did. The icing on the cake would be if a 5/8 nipple could be added for the heater core return line. It would get rid of the plastic t.
Anyways,I love the Zetec so far. I used a new motor I got from the Jim and Brady so I am slowly breaking it in. I just developed a problem with not being able to shift into 3/4 gear so I t h ink the slider is going bad.
It sure does look nice in your van Alaric.H Hope you have a blast with it.

Bill

Tue Jun 01, 2010 8:33 pm

Alaric,

That looks like the highest ground clearance I've yet seen with a Bostig, most impressive.

Can you tell us what your wheel center to top of wheel arch measurement is, please?

Related thread:
Bostig drivers, show us photos of your rear end
http://www.thesamba.com/vw/forum/viewtopic.php?t=367076

Thanks,
-CJ

Tue Jun 01, 2010 11:02 pm

I would love to do the bostig conversion for my syncro if I could get it through our smog regulations here in Reno. I guess I'll have to wait until I move, but hopefully they are working on it for the potential CA buyers. My guess that what works there will also be compliant here.

Wed Jun 02, 2010 3:37 am

climberjohn wrote: Alaric,

That looks like the highest ground clearance I've yet seen with a Bostig, most impressive.

Can you tell us what your wheel center to top of wheel arch measurement is, please?

Related thread:
Bostig drivers, show us photos of your rear end
http://www.thesamba.com/vw/forum/viewtopic.php?t=367076

Thanks,
-CJ Sorry these are pictures of Brady's Syncro he stopped over to say hello and drop off a couple of parts.I did not think to measure the wheel wells.

Sun Jun 20, 2010 9:26 pm

I bought a 2WD 87 Carat on ebay in March 2006. It was a good buy and I love it. But it had the wrong coolant in it and I knew on the 1000 mile drive home already, that I had a headgasket problem. So I babied it and checked and replaced coolant very regularly, never drove top speed and got along just fine. Even took it on a road trip from Canada to Arizona and back. No problem, just check and top up coolant every morning and hope for the best.
In Winter of 2008 I was late for a doctors appointment and gave it the pedal to the metal treatment. Ran great, then blew some plastic end from the cooling system and overheated. At that point I didn't raelly care anymore since I had known a long time I would need a motor. I had spent a lot of time comparing and researching conversions.
For me the Bostig seemed the right one. I am not a mechanic but have learned to find information for my Van on the web and do some stuff myself. The Bostig team is absolutely amazing when it comes to instruction videos, and helping on the phone. Extremely courteous, professionell and very knowledgable. I was able to put the motor in myself due to the good instructions.
So far I have 4200 miles on it and I love the fact, that I do not have to check the vitals of my engine everyday. The power is not amazing but ample. Ground clearance is a bit of an issue and I just decided to order the High clearance Oilpan which is optional.
Cost also tends to be a liitle higher if you are in Canada, since our parts stores and wreckers charge quite a bit more then in the USA. So the used motor and other parts (used alternator, AC compressor, Air filter box, etc) all cost a little more in Canada.
This conversion was not cheap but gives new life to a vehicle we as a family really like.

Sun Jun 20, 2010 9:53 pm

There was a question regarding ground clearance so I took some measurements:
1987 VW Vanagon Carat Wolfsburg Edition
(lower from factory with the alloy rims)
Bostig 2.0 Conversion installed in 2009
Rear Wheelarch hight: 28"
Cradle to ground: 4 3/4"
Oilpan to ground: 4 1/2" (lowest point)
Tires: Rear: 195R14C Front: 185R14C
I drive gravel and dirt roads daily and sometimes off road (as a farmer would do to get to a tractor, not as a 4x4 enthusiast would do in Moab) and have put 4200 miles on this conversion. Yes, I have bottomed out, but I haven't done any damage, other then scratched some paint of the cradle and oilpan.
There is a Oilpan that comes with the conversion, that has better ground clearance, but I decided to leave the Ford Focus Oilpan on there until I got better feeling for the used motor. So this is probably the lowest you can get, but in all honesty, it is not as bad as it looks, when you remember not to stradle high objects in the middle of the van.

Tue Apr 05, 2011 11:55 am

Took about 20 minutes to modify the dipstick during the install to adjust for the access door in my Doka (which is larger than the Vanagon). No reason it won't also work with a van. All the parts are just modified from stock. I did have a different handle and decided to use it instead. I can send photo's upon request, as I can't seem to post them here.