Syncro Westy Build Log - With Pics

Hodakaguy · Posted: Sun Apr 21, 2013 6:59 pm Post subject:

Installed the drivers side axle assy, also installed the speed sensor on the axle and wired it into the harness. Adjusted the brakes on the drivers side and installed the grounds on each side of the engine to the frame, the welding cable will allow for plenty of flex.

Image may have been reduced in size. Click image to view fullscreen.

The RMW speed sensor. It's basically just a hall effect sensor that counts the teeth on the ring mounted to the CV then feeds the pulses to the ECU so it knows how fast the vehicle is traveling. The RMW unit is well thought out with a heavy duty powder coated bracket and easy gap adjustment via the jam nuts on the sensor itself.

Other units available on the market require you to just bend the tab to set gap...

Ran the RJES throttle cable, wired the radiator fan and installed the powder coated spare tire carrier. I'll eventually fabricate a custom storage unit that will take the place of the tire carrier but for now this fills the spot.

Throttle setup. The throttle seems to work really good set up like this, The clamp holding the ball end on the throttle arm is temporary...once I confirm proper placement of the joint I will remove the arm and weld on a tab for the ball end to bolt to.

Getting really close to the test drive now Smile

Hodakaguy
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My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

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Hodakaguy · Posted: Mon Apr 22, 2013 7:24 pm Post subject:

Had a few minutes after work to do something on the bus...thought I would modify the Tach so it will work with the Subaru engine. The original engine uses a different signal to the Tach than the Subaru so the Tach won't work without a couple modifications.

First up...remove the instrument cluster.

Then carefully remove the Tach assy.

This is what were after...the circuit board on the back of the Tach. To make the Tach work with the Subaru you need to remove the 3.32K Resistor out of the circuit and then replace the 1K resistor with a 1/2 Watt 220K Resistor.

Parts removed and ready to solder in the new resistor.

And the new resistor soldered in place.

Now it's just re-assembly time and you have a working Tach.

The instrument cluster is made from a plastic that gets very brittle with age, even though I was careful there were several small areas that had formed cracks around the screws. I repaired the cracks with a two part plastic epoxy and will let it cure for 24hrs before re-assembling the dash.

Hodakaguy
_________________
My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

My Tacoma Builds: https://advrider.com/f/threads/hodakaguys-overland-tacoma-builds-on-to-new-adventures.1274770/

My 4wd Sprinter Build here:https://www.thesamba.com/vw/forum/viewtopic.php?p=9334401#9334401

Syncromikey · Posted: Mon Apr 22, 2013 9:02 pm Post subject:

Ok now that's cool!!!! I've got to book mark this page for sure. I'm hoping to use the Subaru cluster eventually but would like to get the beast on the road ASAP! Or so says my wife ... Get it out of the garage or I'm having a garage sale! I digress ... Looks like a fix even I could do! Shocked

Thanks for posting that!

Cheers,
Mike
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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

Hodakaguy · Posted: Mon Apr 22, 2013 9:18 pm Post subject:

The instructions came with the RMW kit....but was lacking in pics so I thought I'd post some up. Glad it helped Smile

Hodakaguy
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My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

My Tacoma Builds: https://advrider.com/f/threads/hodakaguys-overland-tacoma-builds-on-to-new-adventures.1274770/

My 4wd Sprinter Build here:https://www.thesamba.com/vw/forum/viewtopic.php?p=9334401#9334401

syncrodoka · Posted: Mon Apr 22, 2013 9:18 pm Post subject:

On one of my conversions I did that mod, the other got a 7k tach out of a jetta. The jetta tach has a small barely noticeable gap at the bottom but I like that one better since the needle sweep doesn't go all the way across to the far end of the gauge when reaching redline and it is a little easier to see. It is also plug and play.
Just another option. Wink

specialev · Posted: Tue Apr 23, 2013 11:41 am Post subject:

It's looking really good!

What kind of oven are you using to powder coat? Seems like you've done some pretty big stuff, like that spare tire cover.

Hodakaguy · Posted: Wed Apr 24, 2013 6:41 pm Post subject:

Hodakaguy · Posted: Wed Apr 24, 2013 6:42 pm Post subject:

Hodakaguy · Posted: Wed Apr 24, 2013 6:43 pm Post subject:

Tach re-installed and working Smile

Link

Hodakaguy
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My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

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My 4wd Sprinter Build here:https://www.thesamba.com/vw/forum/viewtopic.php?p=9334401#9334401

SCM · Posted: Wed Apr 24, 2013 7:04 pm Post subject:

My wife just said "that looks like a stormtrooper - SICK!". And now is amped to help out with our spring time "van projects". Thanks!
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'91 Westfalia GL Automatic (GTA "Turbo" Rebuild w/Peloquin) and 2.3L GoWesty Engine

luVWagn · Posted: Wed Apr 24, 2013 9:50 pm Post subject:

ALIKA T3 · Posted: Thu Apr 25, 2013 12:56 am Post subject:

Phishman068 · Posted: Thu Apr 25, 2013 4:04 am Post subject:

Not a diesel, that's a regular US model WBXer equipped Tach. Technically a '86+ tach if you had to make the mod. For whatever reason, '85 tachs work fine.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=559766&highlight=winter+rust
http://www.thesamba.com/vw/forum/viewtopic.php?t=482402&highlight=sunroof+syncro
http://www.thesamba.com/vw/forum/viewtopic.php?t=569774
http://www.thesamba.com/vw/forum/viewtopic.php?p=6864936#6864936

"Along with the ability to go fast, one looses the desire to hurry."

Hodakaguy · Posted: Thu Apr 25, 2013 4:31 am Post subject:

Hodakaguy · Posted: Thu Apr 25, 2013 4:31 am Post subject:

Hodakaguy · Posted: Thu Apr 25, 2013 8:15 pm Post subject:

Lots of work today...not a lot of pictures.

Installed Hushmat in the rear of the bus this morning.

Installed the transmission vent line, I forgot to install it when the trans was out. If you are installing a Syncro trans install the vent line before re-installing the trans, it's a real pain to install afterwards! Packed and installed the passenger side rear axle, adjusted the pass side rear brake, cleaned the coolant overflow tank and filled it with coolant, checked alignment on the engine carrier and torqued all bolts, and I'm sure some other things I'm forgetting.

It's finally ready to be driven on a test drive! Smile

.....BUT.....To get it out I need to install the bare rims again to clear the garage door. First up remove the big brake calipers and rotors, I'll just hang the rotor for now out of the way with a wire. Jacked up the front end, removed the pass side tire and brakes and went to mount up the 14" wheel....BUT I can't find the lug nuts for the steel wheels anywhere! The ones from the aluminum wheels won't work. Sooooooo the bus will spend one more night in the garage, I'll borrow a set from the friend Mike in the am. Test drive tomorrow!

Jacked up and waiting for lug nuts.

Had the garage door partially opened today and the sun was shining through the rear rack...thought the shadow looked pretty cool.

More Tomorrow.

Hodakaguy
_________________
My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

My Tacoma Builds: https://advrider.com/f/threads/hodakaguys-overland-tacoma-builds-on-to-new-adventures.1274770/

My 4wd Sprinter Build here:https://www.thesamba.com/vw/forum/viewtopic.php?p=9334401#9334401

Hodakaguy · Posted: Fri Apr 26, 2013 8:36 pm Post subject:

Ok...up early and ready to get this baby out of the garage. My friend Mike stopped by to help roll it out, with some sleep we finally realized the reason our lug nuts weren't working...without the rotor installed on the front the studs stick out to far and allow the nuts to bottom out, when we rolled the bus in the garage it still had the factory rotor on it as a spacer.

Soooo we just added washers on the studs to take the place of the rotor...and the wheels were quickly bolted up.

Finally outside!

Bleeding the coolant system.

A quick test drive to Mikes house, checked the OBD2 system, no codes Smile

There is a hunting of the throttle at idle before it gets fully up to temp, it comes and goes and if left alone gets worse and worse. The fuel trim was around positive 3, I'll check into it further.

Getting hot outside and not being able to roll the passenger window down just isn't going to cut it. I removed the passenger power window reg and installed a manual reg like the one on the drivers side...much better Smile

(I know I know don't remove the power windows....but I actually prefer the manual windows in the bus).

Did about 60 miles around town today, everything is running really good. This evening I had a coolant leak develop on top of the surge tank at the O-ring where the coolant level switch screws in. I tightened it up some more and it seems to have stopped leaking. I'll wash the engine bay down tomorrow and clean the coolant off the exhaust, might pull the switch and replace the o-ring with a slightly larger one. I'll keep a close eye on it for sure...not sure I trust the quality of the aftermarket surge tank yet.

Here's a few random crappy I-phone pics taken on the test drive around town today.

Feels great to be driving it again! Still a few more mods to come, gotta get it ready for camping season now Smile

Hodakaguy
_________________
My Syncro Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=517384

My Unimog Build: https://advrider.com/f/threads/meet-the-trotn-turtle-unimog-u1300l-build.1143869/

My Tacoma Builds: https://advrider.com/f/threads/hodakaguys-overland-tacoma-builds-on-to-new-adventures.1274770/

My 4wd Sprinter Build here:https://www.thesamba.com/vw/forum/viewtopic.php?p=9334401#9334401

Syncromikey · Posted: Fri Apr 26, 2013 8:52 pm Post subject:

Looking really good! Both of you guys!!! Congrats on getting it up and out onto the road. Super jealous. Going to work around the clock this weekend to try and get a shawk done. How did the power feel? Did you get to pull up any hills? Looking forward to hearing more about how you like it and when you're going to make it up here to give me a hand on mine ... Wink

Great work!!

Cheers,
Mike
_________________
Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954


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Syncro Westy Build Log - With Pics
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