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vik
Samba Member
Joined: January 13, 2005
Posts: 204
Location: back in Czech
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 Posted: Thu Apr 20, 2023 11:36 pm Post subject: Re: Build Thread - Offroad spec Syncro |
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Are you replacing the bushings when everything is apart?
On my 86/87 they mostly look ok, but were not in good shape if closely inspected. And obviously few bolts rusted together with sleeve and was super fun to get them out.
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T3 Syncro camper in progress |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Fri Apr 21, 2023 12:02 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| vik wrote: |
Are you replacing the bushings when everything is apart?
On my 86/87 they mostly look ok, but were not in good shape if closely inspected. And obviously few bolts rusted together with sleeve and was super fun to get them out. |
I just sanded them and than painted over them.. a bit of lazy-work but it will get the job done for a time.. I will replace them in the future as i suspect they're not in their best condition, removing the trailing arm or front assembly is not so much of a work, so no problem if i do it again someday.
I actually have very bad gearbox and front diff rubber mounts and i'm restoring them at the moment. I'll take some pictures and describe the process. This endeavour could be a failure from the start, but i'll see what can be done 
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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rogertj
Samba Member
Joined: October 07, 2008
Posts: 505
Location: Tijuana, Baja California. Mexico
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| Posted: Fri Apr 21, 2023 5:06 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Wow great rust work on the chasis!
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Roger
Had a Carbureted ABA after engoing the heck out of it now going for ABA 2.0 Jetta EFI ill put a garrett in to the tin can later or maybe go electric?
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Mon Apr 24, 2023 4:45 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Status updates finally reached the current ongoing situation:
I'm starting the assembly of the undercarriage, slowly but surely. First parts mounted!
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Thu May 11, 2023 11:46 pm Post subject: Re: Build Thread - Offroad spec Syncro |
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Did some restoration on the smaller parts. Sandblasted the diff vacuum container and rust-converted and painted the shaft.
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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Schnippzle
Samba Member
Joined: February 04, 2021
Posts: 288
Location: Swede in London, UK
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| Posted: Fri May 12, 2023 3:52 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Nice shaft.
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1988 Caravelle - FB25B - Syncro converted
2016 MB E63 AMG S - The daily driver
2019 Harley Davidson FXFBS Fat Bob - The leisure |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Fri May 12, 2023 4:55 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| Schnippzle wrote: |
| Nice shaft. |
On some point in the future it will need some restoration work, new rubber and screws. But for now i agree, i have a nice shaft
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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tjet 
Samba Member
Joined: June 10, 2014
Posts: 3533
Location: CA & NM
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| Posted: Fri May 12, 2023 1:50 pm Post subject: Re: Build Thread - Offroad spec Syncro |
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Good idea getting the hardware zinc plated  |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 3051
Location: MD
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| Posted: Sat May 13, 2023 6:42 am Post subject: Re: Build Thread - Offroad spec Syncro |
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What rust converter are you using?
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Sat May 13, 2023 6:53 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| 4Gears4Tires wrote: |
| What rust converter are you using? |
Wurth rust converter. I don't have the product number but i can look it up. It's standard stuff i guess.
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Sat May 13, 2023 6:54 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| tjet wrote: |
| Good idea getting the hardware zinc plated |
Yea, i don't know if anything else gets the job done better than zinc plating
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Mon May 29, 2023 2:03 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Syncro got some work done.
Found the mounting parts and mounted the cooler and coated engine bay with insulation (the original one was toasted).
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Wed May 31, 2023 4:14 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Work continues with hub assemblies. CV protectors and new discs mounted.
Managed to fit the tank too, with new tank mounting kit (previously mounted with some kind of fabric straps..).
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 9615
Location: Western WA
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| Posted: Wed May 31, 2023 10:10 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Those CV boot protectors are cool. But keep in mind the CVs have to cool in some conditions. A low-speed 6.17 offroad spec Syncro wouldn’t worry about CV heat like a lifted freeway flyer Syncro with a 1.8T (and lead-foot). I bet those were requested by the Finnish military or some industrial Syncro user such as electrical powerlines maintenance crews.
Our esteemed member Sir Ragnarhairybreeks (Alistair) made an elegant copy of those with Stainless steel etc. I have the set in Seattle if anyone is interested to negotiate a sale with Alistair (Ill send them in the US). Alistair makes only one of everything special - then he gets onto another project and forgets his excellent past projects.
Are those OEM X-Joints? I’d test-drive that propshaft on another Syncro for quietness,
and if its smooth, I’d drill & grease those golden bits.
It’s quite satisfying to see the old grease coming out, followed by clean grease.
I did it twice in a “shorter interval” to ensure all the old grease was ejected.
The joint only bends 4 degrees but it definitely mixes grease because the 2nd grease changed from red to black.
Syncro-Needle grease original driveshaft u-joints
I’d also clean & re-grease the brass Guibo bushing every 20 years or so.
It can be ruined, and will allow shaft vibration.
I don’t know what to do if the Guibo is bad.
Nor do I know its purpose.
Perhaps to preserve the VC?
Perhaps to “not pre-excite” the VC?
Who knows?
I suppose the Guibo yoke can be turned down and thicker brass bushings used?
Quieting an OEM shaft is a rabbit hole that’s not fun (from what I hear).
My (2) shafts are quiet and I did everything I could to preserve them as “quiet”.
But before all this preservation work, I’d test it first for smoothness, at the “proper Syncro propshaft test speed” for your specific R&P.
_________________
'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 |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Thu Jun 01, 2023 12:02 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| Sodo wrote: |
Those CV boot protectors are cool. But keep in mind the CVs have to cool in some conditions. A low-speed 6.17 offroad spec Syncro wouldn’t worry about CV heat like a lifted freeway flyer Syncro with a 1.8T (and lead-foot). I bet those were requested by the Finnish military or some industrial Syncro user such as electrical powerlines maintenance crews.
Are those OEM X-Joints? I’d test-drive that propshaft on another Syncro for quietness,
and if its smooth, I’d drill & grease those golden bits.
It’s quite satisfying to see the old grease coming out, followed by clean grease.
I did it twice in a “shorter interval” to ensure all the old grease was ejected.
The joint only bends 4 degrees but it definitely mixes grease because the 2nd grease changed from red to black.
Syncro-Needle grease original driveshaft u-joints
I’d also clean & re-grease the brass Guibo bushing every 20 years or so.
It can be ruined, and will allow shaft vibration.
I don’t know what to do if the Guibo is bad.
Nor do I know its purpose.
Perhaps to preserve the VC?
Perhaps to “not pre-excite” the VC?
Who knows?
I suppose the Guibo yoke can be turned down and thicker brass bushings used?
Quieting an OEM shaft is a rabbit hole that’s not fun (from what I hear).
My (2) shafts are quiet and I did everything I could to preserve them as “quiet”.
But before all this preservation work, I’d test it first for smoothness, at the “proper Syncro propshaft test speed” for your specific R&P. |
Regarding CV protectors, a valid concern for higway fliers in my opinion, but i'm afraid this syncro won't see alot of highway speeds as i do not live near a highway and the nearest straight road that is longer than 200m is 30min drive away
Thank you for all the infos on the shaft, i will surely use it when i tackle the proper shaft restoration, sadly the only syncro in our part of the country that i know off belongs to my brother which too is not drivable (restoration just started). So no testing for me until my syncro rolls.
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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dougnlina
Samba Member
Joined: January 19, 2016
Posts: 246
Location: San Francisco, CA
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| Posted: Thu Jun 01, 2023 4:54 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| TinyPickle wrote: |
| tjet wrote: |
| Good idea getting the hardware zinc plated |
Yea, i don't know if anything else gets the job done better than zinc plating
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Make sure your plater did a post-bake, Hydrogen embritlement is a real thing, you can do your own post-bake if necessary.
https://zincplating.company/hydrogen-embrittlement-what-it-is-and-how-to-combat-it/
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"Olive" a '60 Ragtop Beetle
"Grover" a '87 Syncro Poptop 1.8T |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Thu Jun 01, 2023 6:12 am Post subject: Re: Build Thread - Offroad spec Syncro |
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Hm, didn't know that. Thank you, I'll check this.
I bought new screws for all the critical parts though (trailing arms, shocks, carriers...). So i am not so worried even if this happens 
_________________
God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 9615
Location: Western WA
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| Posted: Thu Jun 01, 2023 7:56 am Post subject: Re: Build Thread - Offroad spec Syncro |
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| dougnlina wrote: |
| tjet wrote: |
| hardware zinc plated |
Make sure your plater did a post-bake, Hydrogen embritlement is a real thing |
Yes it is for 12.9 bolts…… and “somewhat” for 10.9 bolts.
Hydrogen embrittlement is not a concern for 8.8 bolts.
Especially those that don’t hold the van up.
The bolts holding the shifter bushing bracket on the gearbox-not a worry..
For example the four bolts holding the steering rack on.
It’s critical that they don’t all break at the same time.
They won’t break at all, ever, much less all four. (So no worries there).
Some suspension bolts are critical.
Agreed it’s not fun doing an engineering evaluation of a long list of bolts.
Narrow your concerns to the bolts that cause catastrophe if “one bolt” breaks.
Such as a front suspension-arm pivot bolt.
The list of bolts to worry about is short.
_________________
'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 |
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tjet
Samba Member
Joined: June 10, 2014
Posts: 3533
Location: CA & NM
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| Posted: Thu Jun 01, 2023 1:24 pm Post subject: Re: Build Thread - Offroad spec Syncro |
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Yeah I plan to get some critical things zinc'd when I "do" my syncro. Specifically, the front and rear control arms, subframe, and any other low structural pieces that may get submerged in water.
I'm not sure if you've seen this thread, but I think he re-plated every bolt... 
https://www.thesamba.com/vw/forum/viewtopic.php?t=592734
https://lagalvanizing.com/ |
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TinyPickle
Samba Member
Joined: December 15, 2021
Posts: 177
Location: Slovenia, Europe
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| Posted: Thu Jun 01, 2023 10:38 pm Post subject: Re: Build Thread - Offroad spec Syncro |
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Yes i've seen this. One of the most crazy detailed jobs i've seen on the samba. I was wide-eyed the whole time i scrolled through it
It's a great example of a job well done
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God of rust, have mercy.
WIP - Offroad Spec Syncro - 1.9 TDI AFN - Build Thread
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
IG: syncro_brothers |
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