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syncrogreg Sun Oct 24, 2010 8:33 pm

ALIKA T3 wrote: Good work on this van :shock:

Looks super clean!!

I was going to ask you if you were on T3zone also,but Jabba did it first :wink:

Where do you plan to go around the world?

I'm doing the road from Seattle to Chile within the next 2 years if everything goes well :wink:

Bye!!

Cool I'm glad that you're asking that!

This will be modified anyway ... here is the basic idea:



Sorry for the quality, it's a phone picture

ALIKA T3 Sun Oct 24, 2010 8:43 pm

sounds awesome man!!!

Opposite route of mine,but who know,maybe we will hang out somewhere!!

I' m actually doing experiments ,in fact I'm done with the thinking,to cross the Darien gap cheaper:put the westy roof on the side,on a prebuilt pvc rack made with fittings,and on the parking lot,I'll remove springs and shocks to put old welded shocks (no suspension),just to drive it in the container,so it can be less tall than 180cm,cheaper,otherwise you pay by the volume,cubic meters of your van:bummer!it costs more to cross that region than to ship the van from Brazil to USA :cry:

Bye!

Keep in touch!

syncrogreg Sun Oct 24, 2010 9:10 pm

ALIKA T3 wrote: sounds awesome man!!!

Opposite route of mine,but who know,maybe we will hang out somewhere!!

I' m actually doing experiments ,in fact I'm done with the thinking,to cross the Darien gap cheaper:put the westy roof on the side,on a prebuilt pvc rack made with fittings,and on the parking lot,I'll remove springs and shocks to put old welded shocks (no suspension),just to drive it in the container,so it can be less tall than 180cm,cheaper,otherwise you pay by the volume,cubic meters of your van:bummer!it costs more to cross that region than to ship the van from Brazil to USA :cry:

Bye!



Keep in touch!
Cool!
Yes I will be happy to share some road with others Vanagons!!
I just double checked the standart Ocean Freigt containers sizes and the door height is 2.28 cm . So this is what I keep in mind to build my syncro. Lets do some more research and figure it out.

GB

ALIKA T3 Sun Oct 24, 2010 9:27 pm

the container size is one thing,what they charge to you is another thing...you have to be smaller than 180cm,like this they charge you like a car.Otherwise it's way more bucks!!

I have a bunch of links on how to do,where to book etc...and ports to avoid in Colombia.
I also have a colombian guy working with my french surf buddy here,he lived by the 2 major ports where they do the freight on the caribbean side.

I also got in touch with another french guy who is on this trip ,maybe at the same time.
He did it with a motorcycle.

There's abunch a website talking about it,and a guy from Denmark recently finished his trip too around the world.

Bye!

syncrogreg Mon Oct 25, 2010 7:49 am

As I've seen multiple decoupler designs on the market, I wanted to group them on a post (most pics from MG, Thanks MG).

THE US DESIGNS

From Gowesty $995:




Other US designs:

with ball bearing on the actuator:



Without ball bearings at all :shock: (similar to Go westy one):





THE GERMAN DESIGNS

From Syncro-services OR Busschmiede :

The kit 470 euros:



pre-assembled 695euros:



Is also available with a special design on the teeth for easyer engagement... see picture below that compare a stock cone.



The one i got is the German made Kit That seems to me the more complete and robust. The needle bearing on the pinion shaft make me feel good as there is a lot of radial constraints in this area. I really like how the parts goes together compared to SOME other design that really have poor quality of machining and tolerancing.


GB

buspor63 Mon Oct 25, 2010 2:10 pm

Greg,

How did you decide to order a kit from Europe instead of getting a ready to use one from, say AA Transaxle? The exchange rate plus shipping would come close to canceling any savings, wouldn't it? Does it end up being a "better" part? Is it bolt in or is there machining envolved? Sorry for the tedious questions that you may have already answered, but I'm at the point of ordering one.

Corwyn Mon Oct 25, 2010 2:36 pm

Leave the sliding door open, grab a snow shovel, and start filling the van with $...

syncrogreg Tue Oct 26, 2010 9:10 am

buspor63 wrote: Greg,

How did you decide to order a kit from Europe instead of getting a ready to use one from, say AA Transaxle? The exchange rate plus shipping would come close to canceling any savings, wouldn't it? Does it end up being a "better" part? Is it bolt in or is there machining envolved? Sorry for the tedious questions that you may have already answered, but I'm at the point of ordering one.

Hi,
The decoupler I choose to buy is to me the most robust decoupler on the market. I like the idea that I will assemble it too as i like to machine. the total cost was 900 dollars including a VERY nice solid shaft. I ordered 6 month ago a decoupler from the big website and I was very disappointed of the quality and i had to send it back.

The choice of buying this decoupler is personal, I'm sure some US design works very well. Just make sure that you get what you paid for.

GB

syncrogreg Sun Nov 07, 2010 5:20 pm

I installed the drawer yesterday and welded the swivel plate. I think the drawer from RMW are ok for the price. They have some geometry issues but works fine.







GB

syncrogreg Sun Nov 07, 2010 5:51 pm

I started to design my bumpers using the one that are avillable on the market but still making my own touch. I wanted to do t hat before I paint the van as the welds and the risk of scratch is high :shock:



CAD drawing of the rear one



GB

BusJunky Sun Nov 07, 2010 6:22 pm

Great work Greg. I cant belive you scored a syncro like that and for the record im a welder/fabracator who welds/tacks all the time w/o gloves lol. Gotta keep it flush!! Did you cut that entire top off with a metabo? Also flap discs with a fine grade do wonders at sanding those remaining welds w/o really tearing into the thin gauge steel. This tread is making me wanna find a doner westy for my 84. Thanks for sharing brotha!!

ALIKA T3 Sun Nov 07, 2010 6:23 pm

Sweet!! 8)

syncrogreg Tue Nov 09, 2010 9:23 am

RiveraRambler wrote: Great work Greg. I cant belive you scored a syncro like that and for the record im a welder/fabracator who welds/tacks all the time w/o gloves lol. Gotta keep it flush!! Did you cut that entire top off with a metabo? Also flap discs with a fine grade do wonders at sanding those remaining welds w/o really tearing into the thin gauge steel. This tread is making me wanna find a doner westy for my 84. Thanks for sharing brotha!!

Thanks,

What is a metabo? I cutted the roof with cut off wheel, hammer chisel...
I used flap discs to remove the weld and I agree with you that they do wander!

Tacking with gloves is just inacurate 8)

GB

ALIKA T3 Tue Nov 09, 2010 1:11 pm

Metabo is a power tool brand,may be he wanted to say a tool that clips metal?I don't know how to say it in english,but in french it's "grignoteuse":you can cut sheet metal etc....people who work with drywall frames are also using it.

Keep posting 8)

syncrogreg Thu Nov 18, 2010 12:04 am

I got some mild steel tubing, 2.5 in OD .092 wall thickness. Today I bent the 20 degrees angle with a pipe bending machine.
I packed the inside of the tube with sand+water, compacted it and plugged each end with duct tape.

It's hard to start from scratch...


I pre-heated the tube with a torch so inner bends stay smooth with no waves. It worked pretty well for now.




I tried to bend 90 angles but It does not work well so I will eather do like that : http://www.youtube.com/watch?v=cquCfvsvoq0

Or try to find some 90 elbows and 45 for front bull bar.

Please pm me if you know a place or website that have 90 elbow 2.5 in OD with wall thikness .095 to .125in Thanks

GB

insyncro Thu Nov 18, 2010 9:09 am

Greg
Have you picked an engine yet?
Subaru diesel please.

dylan

syncrogreg Thu Nov 18, 2010 9:14 am

insyncro wrote: Greg
Have you picked an engine yet?
Subaru diesel please.

dylan

Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know :D

GB

insyncro Thu Nov 18, 2010 11:17 am

syncrogreg wrote: insyncro wrote: Greg
Have you picked an engine yet?
Subaru diesel please.

dylan

Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know :D

GB

I know two different fellows making adapters to be able to use the Vanagon steering pump on EG33 and EZ30 motors.
Not super difficult to do.

dylan

BlackDogVan Thu Nov 18, 2010 2:09 pm

syncrogreg wrote: insyncro wrote: Greg
Have you picked an engine yet?
Subaru diesel please.

dylan

Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know :D

GB

What criteria are you using to choose the engine for your ultimate expedition syncro?

Awesome progress so far BTW, we've been without a killer build thread for too long!!

syncrogreg Mon Nov 22, 2010 10:51 am

BlackDogVan wrote: syncrogreg wrote: insyncro wrote: Greg
Have you picked an engine yet?
Subaru diesel please.

dylan

Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know :D

GB

What criteria are you using to choose the engine for your ultimate expedition syncro?

Awesome progress so far BTW, we've been without a killer build thread for too long!!

Thanks!

I considered respectively : swap that was never done before, price, common rail diesel, weight, Ground clearance, lid clearance, efficiency and part availlability.

Part availlability in last because i hope I will end up with the subaru diesel :lol:

It's hard to answer that question as VW Vs Sub as different pro and cons that compensate each other. The subaru diesel is definitly the best one to me but pricy :(

GB



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