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0cean Thu Nov 08, 2018 1:46 pm

Well. Now is a time to give a massive thank you to Burley Motor Sports for going the extra mile. Maybe 2 miles. I had a problem with the front ends shock mounting and was missing two very rare collar insert things. This is an item that is not sold or manufactured, and as far as i know, can only be obtained from a factory Syncro. I called up burly and let him know the situation and he not only gave me the parts, but also took the time to pull them from his syncro parts. Most people wouldent let go of such a rare item, let alone take time and do some wrenching to give it to another guy. Thank you very much Burley.

https://burleymotorsports.net/

Here is the front end all put together. Everything was sand blasted and powder coated to restore the glory.




Since i was on all fours for the first time, Had to roll it out and look at the paint job. Sexy, Sexy, if i do say so my self.










O-yeah, had the windows tinted and installed also.

[email protected] Thu Nov 08, 2018 4:11 pm

Very sexy! Great job. Great color.

Steve Arndt Fri Nov 09, 2018 9:59 am

Rad build out. Subscribing just read through the thread. What front brakes?

0cean Fri Nov 09, 2018 10:41 am

They are going to be G-60's, yet i wish they where a Wilwood setup. I know it can be done and it would make pad changes so easy in the future, but it requires fabrication. I am all out of extra fabrication patients. Maybe at a later date.

I had some old pictures of the G-60 rebuild, but i cant find them at the moment.

Steve Arndt Fri Nov 09, 2018 11:28 am

On my Syncro I am using epytec adapters, G60 calipers, and 312x25 bigger Audi rotors. Over 1" more rotor diameter should give some extra brake torque. For the rear I'm planning 25mm VW LT wheel cylinders and semi metallic shoes.

0cean Tue Feb 12, 2019 11:34 am

Well, this thread has been at a snails pace due to DMV titling issues. It's prevented me from working on it until the paperwork is completed. Now its titled the way it should be, so more will be coming on the build.

I did get the top on, front bumper, and rear door is in place. The windows where also added with tint. Not crazy dark with the tint, just enough to keep the sun off.

Nice to see it on the road...Well kind of...





D Clymer Tue Feb 12, 2019 4:44 pm

Keep up the good work, Jason! It's really nice to see this project nearing the final stretch. Can't wait to hear about the drivetrain installation.

D

msinabottle Wed Feb 13, 2019 11:01 pm

How proud you must and should feel! And that GULF when you look back to when you started...

Best!

0cean Wed Mar 06, 2019 3:33 pm

Little update, this storage area was built some time ago, but what I didn't take into account was the weather stripping. The whole box was really tight as it was, but now it needed grease and a floor jack to put it in. Don't think it will ever fall out even if I want it to.

Anyways, the out side 120 volt power converter was added to the front of the box and installed permanently. Thank god something is getting done finally.









markswagen Tue Apr 23, 2019 8:12 am

Looking good Jason, I'll stop by for a look see when I'm next in your neighborhood.

0cean Mon Jul 01, 2019 8:36 pm

Well, I've been working and building stuff for work, so the van has been a little left behind lately. Its not forgotten. Had a little time to work on the shore power and extra battery system.


I couldent figure out where to place the plug in for shore power. I knew it should be in the front so i can drape the power cord over the front windshield wiper. This is importiant because i know myself and will drive off with it pluged in. So this is what i came up with.














Still needs to be cleaned up and finished, but most of the work is done. Im not sure how im going to make the front VW emblem removeable, yet im sure it can be figured out.

jberger Mon Jul 01, 2019 8:42 pm

Spring loaded hinge obviously....

0cean Tue Jul 02, 2019 11:02 am

jberger wrote: Spring loaded hinge obviously....

Not sure if its that easy. The VW emblem needs to move forward about one inch and then drop down. I think the hard part will be how to keep it in place so it cant be shaken out of the holder.

[email protected] Tue Jul 02, 2019 4:12 pm

Super strong magnets?

0cean Wed Jul 31, 2019 1:56 pm

Little Update, Here are the finished pics of the shore power outlet. Turned out good. For the VW emblem i just shaved a little off the tabs and now its snug fit, yet removable. Good enough.







I realized the transmission is not clearing the rear center frame member the way i wanted, so its getting cut. Yes I'm cutting my Vans backbone. I am installing a 1/4 metal plate to add structural strength though. Its not pretty, but it will hold. Still need to clean up the weld drips a little.




rfoubi Wed Jul 31, 2019 9:02 pm

Amazing attention to detail, as usual! Did you cut the whole crossmember out, and then weld the new plate in? Is it custom (new steel?) I am contemplating doing this to mine (rusted out tranny mount) and debating trying to cut pieces from a donor van or just use new metal.

0cean Thu Aug 01, 2019 12:35 pm

rfoubi wrote: Amazing attention to detail, as usual! Did you cut the whole crossmember out, and then weld the new plate in? Is it custom (new steel?) I am contemplating doing this to mine (rusted out tranny mount) and debating trying to cut pieces from a donor van or just use new metal.

Its just a added piece of fresh metal. I need the extra support for when i cut into the crossmember. When the mod is done, it will be a lot stronger then factory, just going to be a little weak until finished.


I would be very careful with replacing the crossmember. It holds the entire rear end in place in a straight line. Removing it and rewelding a new one in its place would be very hard to do without a car frame table. Not impossible, but a very quick way to wreck your van if not done 100% right.

Maybe added metal on both sides of the crossmember and then cut out the tranny mount area from the bottom would work? Hard to tell the best way to approach it without pics.

0cean Wed Aug 14, 2019 10:08 am

Well I'm breaking its back. Finally cut into the main rear support. Its amazingly thin metal. I thought it would be very reinforced, but the grinder made easy work of it.




I made a transmission mount support out of .25 plate steel. Its way stronger then OEM.





Unfortunately the mount bracket was an inch and a half to short. Not the end of the world, just need a little more cut and weld to make it right. The transmission mounts are motor mounts from a Jeep wrangler TJ and very available in the future.



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