Syncro Westy Build Log - With Pics

[Welchmaster]

I think you and Mike need to come to NW Mogfest this year!
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90 2wd Orly Blue Multivan weekender. "Van-Duzer"

"Further up, further in!"

[MasterMarine]

[Hodakaguy]

[Hodakaguy]

[Hodakaguy]

Ok...time to get started on the fridge project. Started removing the fridge today and quickly got side tracked on another project lol.

Removed the fridge door and the trim around the fridge. Yep...this is where I got side tracked already. Thanks to another Samba member I got the idea to use the old fridge door as a new closet access door. Before I cut the trim piece to match the new fridge I wanted to use it as a pattern for cutting the new door in....soooooo better get that out of the way now

Separated the fridge door from the cabinet door.

The closet is pretty deep and has a lot of storage capacity, unfortunately the only access is the tall skinny door above the rear table (red arrow). It's not very convenient to get stuff in/out and you have to dig around to get to stuff on the bottom.

With the rear door removed I used a square to draw a level pencil line so I could place the trim piece on and mark out the opening. You can see a light pencil outline of the cut out.

Tape applied to keep the laminate from getting scratched. I built a home brew Westy hospital tent to try and control the dust during it's open cabinet surgery

Drilled a small test hole with a hole saw to see how it cut through the laminate. Worked good but you have to go really slow to keep it from grabbing as it goes through the laminate.

Ok...a few more trial cuts with the 4" hole saw and then it was time to cut the corners in.

Used a square and a jig saw to cut the rest of the opening out.

Used a router to cut in a groove for the original trim from the fridge.

And installed. This will make it a LOT easier to get stuff in and out of the closet. Looks like it came this way from the factory!

Door open. I'll make a shelf to install inside so it will be easier to utilize the space more efficiently. The trim is still loose in places in this pic.

Last project for the night, applied some silicone to the groove and taped the molding into place. I'll install the door again in the morning and move on to the fridge install.

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

[Farfrumwork]

Nice!
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sold -> '85 Wolfsburg Syncro / 'Built' DOHC EJ25 (a great machine!)
'07 Legacy spec.B, road tuned stgII
'17 4x4 Sprinter, stone grey, SMB pop-top, on 33"s

"Blood stains, speed kills - Fast cars, cheap thrills - Rich girls, fine wine - I've lost my sense, I've lost control, I've lost my mind"

[Hodakaguy]

Today's progress.

Took the Syncro in for an alignment first thing this am. I knew I had it close with the garage alignment but the steering wasn't quite right, just had a weird feel to it. I wanted to get it checked before it started eating my new tires, I'll have it re-checked after I put 1500 miles or so on it and let the suspension bed in properly.

Well the front was off a bit (figured that) but I had the back close enough that he didn't charge me for tweaking it to exact specs, only charged for a front end alignment. It drives a lot nicer now with a normal feel from the steering wheel. All the T3 Urethane bushings are great, nice solid feel in the front end!

Next up...Propex heater install.

Headed to my friend Mike's house and pulled the stock fridge.

With the fridge out I was anxious to check behind the insulation and see if there is any rust forming. Water can leak in from the outside hook ups and once inside gets trapped and forms rust. I pulled back the insulation and poked around...nice and clean, no rust

Cutting the access holes for the Propex heater. I decided on the under the fridge location since it will take up the least cargo space. I was originally going to mount it under the rear bench seat...but it would take up a large amount of that area and I use that storage space a lot.

My friend Mike recently installed his Propex in this location and so far it's worked great.

Checking layout with the supplied pattern, getting ready to drill the two holes for the intake and exhaust piping.

Holes cut and sub floor removed. I painted the bare metal with POR-15 and later applied a coat of high temp RTV on the edges. You need to get the Propex as low as you can so you can have a air gap between the fridge and the heater.

With temps in the Mid 80's it was getting hot inside the bus...time to roll out the awning. Man what a difference, the interior stayed a lot cooler with the awning out.

Propex mounted in place. I'll be using foil tape to wrap the edges around the openings. Here the cover is open and I'm getting ready to hook up the power and control wiring.

Running the wiring for the thermostat and controller. I'm using these screw on type wire retainers, you just screw them down then slide a snap tie through the slots, makes for a nice neat wire run.

And wiring up the thermostat. Having the new closet door in the rear worked great, had a lot more room to work in there and run the wiring

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

[insyncro]

Pull that fiberglass insulation

[Hodakaguy]

[Hodakaguy]

Fridge work continues....

Measured the trim piece and cut the bottom off. Then had to square up the curved part on the top.

Trim piece back in. I temporarily installed the fridge to see how high I needed to cut the top of the trim piece. I need to mount the fridge as high up as possible to get maximum clearance between the Propex unit/ fridge. I used 3/4" x 2" oak strips to back the trim piece and act as the fridge mount point.

This is the amount I'm removing from the top of the trim piece.

Trim piece installed for good this time.

I ended up using 1"x1" aluminum angle for the fridge bottom mount.

Next up is to fabricate the plate that the fridge sits on. Ended up using 3/16" aluminum plate, then have a 1/4" layer of foil/foam insulation on the top, and then the insulation is wrapped in foil tape so it won't tear when sliding the fridge in/out. This should offer a good amount of heat protection for the bottom of the fridge.

Another test fit of the fridge revealed the need to widen the gap on the right front of the plate to allow the fridge hinge plate to clear. You can see the widened gap in this pic.

Just a little over 3/4" of clearance between the Propex and Fridge. The Propex unit runs really cool and with the heat shield above it shouldn't affect the fridge.

Had to slightly bevel the trim piece at the red arrows to clear the screws on the side of the fridge and allow it to sit flat against the trim piece.

Heater outlet hose in place, wrapped in exhaust header wrap to keep heat out of the cabinet area.

Fabricated the bottom trim piece out of 3/4" thick oak. Had to step the back side down in several areas to get it to sit flush. Cut in the hole for the heater outlet and covered it with matching grey laminate.

And the fridge installed. Cut a piece of matching grey laminate for the fridge door to replace the black panel the fridge came with. I really debated on changing the color of the trim on the fridge from black to grey, now that it's done I'm really glad I did as it looks a lot more factory this way. I will come back and paint the heads of the screws used to mount the fridge to the same color grey as well.

My father made up a block off plate for the flue vent on the side of the bus. A little black RTV and it's nice and water tight.

Tomorrow I'll wire in power for both units and run new propane lines into the bus. Can't wait to try both units out!

Thanks to my Father and to Mike for the help and use of tools the last couple days....long hrs.

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

[purplepeopleeater]

Looks good, I ate lots of sawdust

[Hodakaguy]

[BoneMachine]

[luVWagn]

Great shirt!
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'91 Double Door Transporter

[Syncronoid]

Just an FYI. Check to see that the door of the fridge is turning off the light. I had an issue with the cheap plastic mechanism of the TF49. If not lubed or positioned properly, the mechanism does not engage the disconnection of the light circuit. Placing some tape or other material on the door at the point where it contacts the button ensures that the light turns off when the door is still open an inch or so.

I entertained the thought of the changing the panel color to match the interior, but still haven't made the switch. Your effort make make me revisit the thought.

Cheers!
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'90 Syncro Westy w/GW2.5L

[singler3360]

Nice workmanship. Looks good. What did you use to paint the trim?

[purplepeopleeater]

[BillM]

[quote="BoneMachine"]

[purplepeopleeater]

Dale smokes, but you gave me a good idea for a halloween costume.

[Hodakaguy]