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Pastis, The Ultimate Subaru Boxer diesel EE20 Vanagon Syncro
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syncrogreg
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PostPosted: Sun Oct 03, 2010 9:21 pm    Post subject: Pastis, The Ultimate Subaru Boxer diesel EE20 Vanagon Syncro Reply with quote

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Hi Vanagon Folks,

One day I was spending some time on craigslist looking for a simple vanagon to fix and use as a daily driver. I was not looking for a Syncro because they are rare and very expensive. So I was on craigslist and sundenly I saw an ad that says:

"Classic 1986 Volkswagon Vanagon for sale $750 OBO. Needs TLC and some engine work. Does not run, died due to alternator. Perfect for someone that would want to restore it. Interior is in good condition and exterior has a little rust. Serious inquiries only. "

and looking at the picture I figured that it was a syncro because of the rear tank filler. The day after that I was there with the Uhaul tow dolly, a 8h drive down from Nashville TN to Lexington SC... bought it for 600 bucks, loaded it and took about 10h to come back to Nashville. All this within a 24h tow dolly rental (pickup the wednesday at 6 pm and returned it the thursday at 6:05pm) it was kind of intense but well worth it Very Happy

Then the story began; I decided to make THE ULTIMATE expedition vehicle.

I started a blog on another forum but stopped...I thought that the samba would be the best place to be.
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travel pictures:
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- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel


Last edited by syncrogreg on Fri Dec 03, 2010 2:36 pm; edited 24 times in total
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Sir Sam
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PostPosted: Sun Oct 03, 2010 9:23 pm    Post subject: Reply with quote

I want to win the lottery too!

(you got deep pockets right?)
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IdahoDoug
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PostPosted: Sun Oct 03, 2010 9:30 pm    Post subject: Reply with quote

Welcome! I'm new here as well and doing something similar with a similar vehicle. So let me know what your ideas are for making this into something without a pop top that can support extended trips. I have the additional challenge of having a family of 4, which makes for a challenge to have sleeping space inside the vehicle in addition. For 2, I think these are perfect.

DougM
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syncrodoka
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PostPosted: Sun Oct 03, 2010 10:01 pm    Post subject: Reply with quote

Looking forward to pictures!
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buspor63
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PostPosted: Sun Oct 03, 2010 10:11 pm    Post subject: Reply with quote

Greg,

Glad you found a Syncro, i think you may have inquired about mine some time back. I decided to keep mine and sell the Westy, which I did with in a week.

Good luck with the project, I've had fun with mine so far. Sounds like you made a scaore on the purchase. Like Doug, I hope to convert mine to a usable vehicle for the five of us. I'm looking at installing a rock-n-roll bed, one jump seat and build a pantry behind the driver. long term will be a high top, but so far, none catch my eye.
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syncrogreg
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PostPosted: Sun Oct 03, 2010 10:37 pm    Post subject: Reply with quote

Hey all this sounds good!

Here is the pics of the van when I grabbed it :

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Do you see what I see?
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GB
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conversions:
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travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel


Last edited by syncrogreg on Mon Oct 04, 2010 10:02 am; edited 2 times in total
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syncrodoka
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PostPosted: Sun Oct 03, 2010 10:44 pm    Post subject: Reply with quote

Looks like you have a pretty nice syncro base to start with. It has minimal body damage/rust and has a rear locker- nice score. Smile
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syncrodoka
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PostPosted: Sun Oct 03, 2010 11:22 pm    Post subject: Reply with quote

Quote:
Do you see what I see?
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OMG a sony 20x4 cassette player, lucky you! Is it a pull-out too?
Straight out of the 90's, so retro. Wink


Last edited by syncrodoka on Mon Oct 04, 2010 12:36 pm; edited 2 times in total
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syncrogreg
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PostPosted: Sun Oct 03, 2010 11:27 pm    Post subject: Reply with quote

Doug, Here is my answer of your problem.

I always want more Rolling Eyes

In order to do a Westfalia roof conversion I looked up Craigslist again(Thanks Craigslist) for a camper this time and I found a 1984 1.6 diesel Vanagon Westfalia, in Arkansas! it was the same Uhaul story (24h trip).

Here is what I got for $400:

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I did not lose time to remove what I wanted on the frame:

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Bunch of spotwelds...
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Rough cutted farther than i needed to be safe
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It took me a little while to have this roof section out
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Already positioned in the syncro waiting for few welds Laughing
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GB
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conversions:
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travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel


Last edited by syncrogreg on Mon Oct 04, 2010 7:06 pm; edited 5 times in total
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syncrogreg
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PostPosted: Mon Oct 04, 2010 12:09 am    Post subject: Reply with quote

syncrodoka wrote:
Quote:
Do you see what I see?

OMG a sony 20x4 cassette player, lucky you! Is it a pull-out too?
Straight out of the 90's, so retro. Wink


Not a pull out... I gave it to a Vanagon friend that moved back to Austin, trust me or not, somebody broke the windshield yes the windshield! and stole this radio!!!

GB
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conversions:
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travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel


Last edited by syncrogreg on Mon Oct 04, 2010 7:07 pm; edited 1 time in total
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syncrodoka
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PostPosted: Mon Oct 04, 2010 12:41 am    Post subject: Reply with quote

Too bad that his van got broken into for that.

Last edited by syncrodoka on Mon Oct 04, 2010 5:29 am; edited 1 time in total
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DAIZEE
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PostPosted: Mon Oct 04, 2010 5:28 am    Post subject: Reply with quote

Nice find(s). Like your choice of lighting in the Westy Laughing Those lamps turn into great plant holders Smile CONGRATS on the start of your voyage.
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danfromsyr
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PostPosted: Mon Oct 04, 2010 7:55 am    Post subject: Reply with quote

Congrats on a great series of great deals

I do hope you removed the cneter driveshaft fromt he Syncro before towing it on a 2wheel dolly. or I fear you may have a bad Viscous coupler.

Best of luck and we want more images from the roof swap conversion.

Dan in NY
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syncrogreg
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PostPosted: Mon Oct 04, 2010 8:00 am    Post subject: Reply with quote

danfromsyr wrote:
Congrats on a great series of great deals

I do hope you removed the cneter driveshaft fromt he Syncro before towing it on a 2wheel dolly. or I fear you may have a bad Viscous coupler.

Best of luck and we want more images from the roof swap conversion.

Dan in NY


Thanks,

I was lucky, one of the front cv joint was removed so i did not have any mechanical problem pulling this van 10 hours on the tow dolly. It does not matter because I'm fitting a solid shaft anyway.

I have plenty of pics that are comming!

GB
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conversions:
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travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel
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beelzibus
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PostPosted: Mon Oct 04, 2010 8:35 am    Post subject: Reply with quote

syncrogreg wrote:

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That's a nice score for 400$, As you're obviously breaking it do you fancy helping the UK owner of a Canadian spec Vanagon Syncro Westy out? I'm looking out for a pair of front turn signals and a pair of rear side markers. Euro spec didn't have side markers.
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syncrogreg
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PostPosted: Mon Oct 04, 2010 1:24 pm    Post subject: Reply with quote

Here is more interesting details about the Westfalia roof converion.

the Westfalia roof section into the Syncro.
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Starting the prep of the donor roof, It's pretty much remove all the reinforcement metal parts. They are welded and a little bit hard to deal with. I will say that the hardest part is to not mess up the section you want to keep
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In parralel it's needed to cut the Syncro solid roof. I had couple dog bowls arround and one appeared to be the perfect radius Wink
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Drawing is fine, cutting is different. It's like... I hope I'm not killing my van Rolling Eyes Rolling Eyes
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Once the syncro solid roof is removed it's necessary to weld the attachment plate that have the three threaded nuts that com from the Westy. This plate is thin and easy to bend, It took me a while to get it off clean and straight.
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By the way, because I plan to carry some extra stuff on the roof I reinforced this area. New welder, I had to train on this side...
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I had to make the syncro roof prep as well, wiring and grinding to make it fit like a glove!
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A good antirust application is important for your roof to last looong
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Last adjustments before permanent weld.
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Starting to look like something Smile not welded yet...
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GB
_________________
conversions:
www.boxeer.com


travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel


Last edited by syncrogreg on Mon Oct 04, 2010 7:20 pm; edited 3 times in total
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westyventures
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PostPosted: Mon Oct 04, 2010 1:42 pm    Post subject: Reply with quote

Wow, great scores and start to an awesome project! Hope you saved all the diesel bits to help install that diesel engine you'll want for a world-tour camper. Wink
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syncrogreg
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PostPosted: Mon Oct 04, 2010 2:27 pm    Post subject: Reply with quote

westyventures wrote:
Wow, great scores and start to an awesome project! Hope you saved all the diesel bits to help install that diesel engine you'll want for a world-tour camper. Wink


Hi Karl,
I plan to fit either a 2010 tdi CR (from jetta or golf) or a Boxer diesel that (If one availlable) could get shipped from europe. I like the idea of making the first Boxer diesel Vanagon on the planet but more I think more I want to go with the VW Tdi CR because of replacement parts available during the trip.

few exciting pics
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I sold all the diesel bits as I'm starting all from scratch, I will have to go with a new bellhousing anyway.

Thanks for following!

GB
_________________
conversions:
www.boxeer.com


travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel
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Sir Sam
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PostPosted: Mon Oct 04, 2010 3:22 pm    Post subject: Reply with quote

Both of those swaps are going to be difficult, both are unsupported and undocumented.

I'm doing a similar swap - new common rail VM 2.8 turbo diesel(from jeep liberty, also used in london taxis etc) into an old 87 Jeep Comanche.

Undocumented and never done before, get ready to reinvent the wheel to do either swap.

I too dream of a subaru boxer diesel, getting the engine complete shipped to the US is not the problem(though presents a minor logistics issue in itself). It's dealing with the complicated electronics of the newer Subaru engines.

As Ben has noted several PIC's have the CANBUS built in - which can be used to replicate some of the various functions of the bus system.
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PostPosted: Mon Oct 04, 2010 6:28 pm    Post subject: Reply with quote

Wow, inspirational build! Really nice work so far, looking forward to watching this one progress.
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