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bluntlunchbox Samba Member
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Joined: June 06, 2007 Posts: 330 Location: San Diego, CA
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Posted: Sun Dec 15, 2013 1:21 pm Post subject: |
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Great job on your Syncro and love the holiday pics! Do you have a link to the thread on club80-90? _________________ 1966 Beetle "Old Girl"
1990 Vanagon GL |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 1:21 pm Post subject: |
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thanks again all, The wife will never truly forgive me for selling the previous 3 vans the white one pictured above.. someone drove off in it just as she was getting back from work, never even mentioned it was for sale..
Scott, this is the tip of the iceberg! read the thread on 8090! This is just a recap
forgot to ad the pic after the lift
more to follow.. _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 1:23 pm Post subject: |
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bluntlunchbox wrote: |
Great job on your Syncro and love the holiday pics! Do you have a link to the thread on club80-90? |
its a big thread, lots of rambling conversations.. gets better the longer it goes on
http://forum.club8090.co.uk/viewtopic.php?f=4&t=78449&hilit=big+brakes _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 1:35 pm Post subject: |
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Van is now so high the wife can't see in
More camping at our favorite spot
pic of the 16" spring spacer
So, the handbrake let itself off one day..
new cable fitted
Got on with the big brakes, merc 303mm vented discs, G60 calipers and VW Sharan brake flexi's
new next to old flexi's. Hole in chassis bracket for flexi needs opening up slightly
rear handbrake cables changed over too
just in time..
_________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 2:35 pm Post subject: |
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During the brake work, new boots were fitted too, all genuine VW.
Some proof here of the bmw oil seperator doing its job, breather pipe before and after unit
Now al replaced with oil rated silicone hose
Steering rack bushes next, certainly improved the feel
On to leisure battery side..
Sterling 50 amp battery charger fitted under drivers seat
and a leisure battery befing both front seats
Power also run to the back with it's own fuse box
Compressor fridge fits behind the drivers seat
Decided black is just to dull for coolant hose's, orange and s/steel is just so much better..
By now the white smoke issue was really starting to annoy me, didn't stop me getting a new prop though
and a free camp in view of stonehenge
another free camp by the beach
smoke was steadily getting worse.. Had a check of the timing.. Brilliant looks a fair bit off, could be the answer!
new belt fitted, now runs a lot better, but still smoking.. Anyway no time now, a year has passed and its time for our next euro holiday. Felt a bit more nervy leaving this time, as i new something was wrong with the engine..
fly screens fitted
And we are off!
Stayed in france this time, but still covered a fair amount of ground
The van really behaved well, no breakdowns.. but still smoked like a trooper... _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”
Last edited by lloydy on Sun Dec 15, 2013 3:26 pm; edited 1 time in total |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 2:50 pm Post subject: |
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So, we kinda come up to how it stands now.. Decided to do a compression test and found one cylinder is down around 70 bar, this will answer all my issues.
Instead of repairing this engine, i have gone down the route of getting a new engine built with all new parts. This is still being built now, but heres a few pics of block, new oversize pistons, new flywheel, sump ect ect
And after a clean, mild port, new tappets, seals ect
A brand new flywheel was sourced and paid for
The passat alternator/water pump/ps pump bracket was too mucky for my liking, so it was cleaned and a new bearing pressed in
before
after
And bearings arrived...sputter bearings in the rod and normal in the cap...expensive!
And pistons fitted to rods selectively with pins to get the best possible balance..piston on the left has had a bit of metal removed as it was overweight..
And main bearings in and crank fitted....plastigauge shows oil clearance at 0.05/6 so well within the limit of 0.17.
this is up to date with the engine, now to empty the interior for the bodywork _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Sun Dec 15, 2013 2:59 pm Post subject: |
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stripping the interior, showing 16" and multivan specific stuff..
new back lights
just waiting for the Terrapodz now
van is at the bodyshop now, awaiting surgery. I'll keep this updated with pics of engine and welding.... _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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chojinchef Samba Member
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Joined: February 17, 2011 Posts: 1539 Location: Central Massachusetts
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Posted: Sun Dec 15, 2013 3:20 pm Post subject: |
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Holy crap!
It's like my whole life just passed before my eyes.
Very nice
LP _________________ Its a mistress; an expensive, whiney, needy bitch of a mistress. She is a chunky, dirty girl with bad skin, little motivation and yet she always makes me smile. She sure has been around before shacking up with me. She has a direct line to my wallet, plays with my emotions, is consistantly jovial yet with a sarcastic and sardonic side, is consistant in her inconsistancy, and every once in a while gives me a great ride and a fantastic memory. |
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joetiger ![Premium Member Premium Member](./templates/subSilver/images/lang_english/icon_star.gif) Samba Member
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Joined: January 27, 2005 Posts: 5141 Location: denver
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Posted: Mon Dec 16, 2013 9:23 am Post subject: |
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Great thread and a cool rig! Thanks for sharing! _________________ Joe T.
'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'91 Wolfsburg Carat
'04 Golf R32
"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron
"Still, it's good to be afield."--VWagabond
Check out my book: Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present
www.josephtrussell.com
www.pigpensyncro.com |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 9:31 am Post subject: |
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cheers
From previous pics of the dirty seats and carpet, i got them back almost good as new
Stripping and cleaning the central locking (has never worked)
taken apart
and cleaned up
Still didn't work
perseverance is a trait i have the the wife can rightly hate sometimes....
BUT.....
i've got my central locking working well, some of it..
after looking at Andy's line drawing, and looking on the samba, it finally made sense on how they worked.
I removed the actuators again and stripped them and checked the contact point on the slider thing, this i have realised is where the tiny springs are. Mine had rusted leaving the contact point too far in to make contact
Old springs out, and you can also see the new spring
i had to make the hole for the new springs slightly bigger as the spring i had was bigger
I also put the motors from the two slave actuators in to the master ones, as theses were a lot better looking.
slider actuator all cleaned and fitted
contacts on slider
and contacts on pillar, as you can see one pin has failed, luckily only 3 of the pins are used so just swapped them over
And heres the mechanism in the tailgate for those who want to see how it fits
My next plan for this is to remove the remote locking 'brain' and wiring from a T4 (eurovan) and splice it into the T3 loom, should then have a genuine VW set up, as i'm not sold on the aftermarket kits. The flip key always seems flimsy _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 10:18 am Post subject: |
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I also fitted some relays for the new SA set up, really did make a big improvement
Made up some tails for the relays first
removed the steering column cowl and dropped the fuse board.
Traced the wires from the hi/low switch on the column until they popped out the sheath. It's the yellow and the white wire that are for the lights, can just see them here
Then cut one of the wires
, connected the end from the column to number 86 on the relay and the end going to the fuse board to 87
Then it was just a matter of running a cable from the earth crown to number 85 and a live, which I too from a spare spade on the back left of fuse board to number 30 on the relay. The relays I then mounted to the top of the fuse board
And that was it done... _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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Zeitgeist 13 Samba Member
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Joined: March 05, 2009 Posts: 12130 Location: Port Manteau
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Posted: Mon Dec 16, 2013 11:35 am Post subject: |
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lloydy wrote: |
cheers
My next plan for this is to remove the remote locking 'brain' and wiring from a T4 (eurovan) and splice it into the T3 loom, should then have a genuine VW set up, as i'm not sold on the aftermarket kits. The flip key always seems flimsy |
I can understand your general concern about aftermarket electronics, but in my experience, the MES kits are head and shoulders above the rest. The actuators bolt right up to the VAG brackets, and you can utilize the stock wiring for the slider and rear hatch. I'm fairly certain MES is an OE supplier for other marques. I installed a kit on my van around seven years ago, and have been quite pleased with the reliability and convenience of the remotes. I think I'm on the second set of batteries in the fobs. _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 11:57 am Post subject: |
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I agree.. A few friends have a very similar kit to the one you linked (called rightclick) and report no problems with years of use. I just REALLY want it to work off a vw flip key, i'm a fussy fecker!
on German ebay you can get the whole harness for remote locking for around £100 (eurovan). something i may look at in the future... Maybe when the van comes back from body and engine work.. _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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yycwesty Samba Member
Joined: August 20, 2012 Posts: 403 Location: Calgary
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Posted: Mon Dec 16, 2013 12:00 pm Post subject: |
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Hey Lloydy
Amazing write up..Thank you..Can you tell me about the immobilizer ring. I have never head about this unit..Looks like a good way to improve security or is this a syncro only option (have a 2wd)
Cheers
Al |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 12:04 pm Post subject: |
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Hi, the immob ring is from the donor car that supplied the TDI engine and loom. I just had to keep the key with the chip inside it from the donor, then put the chip in a key for my van. Should be able to be done with any of the TDI/1.8T conversions.
As far as i know, not something you can retrofit to a standard T3 engined van _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 12:21 pm Post subject: |
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one that always bugged me with my van was the lack of illumination when passenger and sliding door was opened, so i decided to fit two more interior lights. One above the passenger and one by the slider
light fits!
above passengers door
And again i didnt make the hole too big!
in the two pics above, the hole and light dont look level.. just a optical illusion, honest.... measures to the mm to the one on the other side and the plastic strip holding the headliner...
just need to run the wires now... i
1, piggyback live, perm earth and switched earth from drivers light over to connection on light above passenger door (passenger door already has wired in door switch)
2, piggyback same wires over to light above sliding door, then take the switched earth down to switch on sliding door.
picked up a delay light off a Golf, this will allow (with the above wiring) all the lights to work as the delay type
After removing the headlining and having a bit of a headscratch on the right way to run the cables i found what seems to be the VW channel for them. Starts off right here above the drivers door
it then appears here above the slider
You just keep on feeding it through and it comes out right by the cut out for the light but on the wrong side of the metalwork. Fortunately VW provide a hole in the metalwork for the wires to go through (copied from the other side) Heres the wires now, waiting for a light to be fitted
The other end by the front door will be attached to a light then carrried over to the drivers side. I still had to run a switched earth from the rear light to down the B pillar for when i get the door switch, it will also be spliced into the existing switched earth circuit (this will mean all the lights come on whatever door is opened)
I followed the same route as the wires for the central locking, so through this grommet (normally hidden by headliner)
and found down here
perfect access to where the switch will be (just above central locking connections)
Contact pad for the door switch on the slider, this is where it goes
and here it is fitted
also the switch for the slider contact, which turned up after the van left
Loom for the lights all wrapped and temp tied up out the way
happy to report it all works, whichever of the 3 doors are opened all 3 lights come on, and all stay on for the delay period too! ![Very Happy](images/smiles/icon_biggrin.gif) _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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kamzcab86 Samba Moderator
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Joined: July 26, 2008 Posts: 8044 Location: Arizona
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Posted: Mon Dec 16, 2013 12:55 pm Post subject: |
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Wow... that's some story and an awesome adventure van!
lloydy wrote: |
The wife will never truly forgive me for selling the previous 3 vans the white one pictured above.. someone drove off in it just as she was getting back from work, never even mentioned it was for sale.. |
If you let this Syncro 16 go, she might file for divorce! ![Razz](images/smiles/icon_razz.gif) _________________ ~Kamz
1986 Cabriolet: www.Cabby-Info.com
1990 Vanagon Westfalia: Old Blue's Blog
2016 Golf GTI S
"Real knowledge is to know the extent of one's ignorance." - 孔子 |
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Zeitgeist 13 Samba Member
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Joined: March 05, 2009 Posts: 12130 Location: Port Manteau
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Posted: Mon Dec 16, 2013 1:15 pm Post subject: |
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lloydy wrote: |
I agree.. A few friends have a very similar kit to the one you linked (called rightclick) and report no problems with years of use. I just REALLY want it to work off a vw flip key, i'm a fussy fecker!
on German ebay you can get the whole harness for remote locking for around £100 (eurovan). something i may look at in the future... Maybe when the van comes back from body and engine work.. |
Perhaps a happy medium would be to use the VW controller and flip key, along with the MES actuators, which I believe are of a superior design. Now I'm kind of intrigued with this idea...hmmm _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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lloydy Samba Member
Joined: September 15, 2010 Posts: 715 Location: cheam surrey
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Posted: Mon Dec 16, 2013 1:21 pm Post subject: |
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That idea was flickering through my mind just now i have a whole set of those MES type actuators... Have a go and i'll copy ![Very Happy](images/smiles/icon_biggrin.gif) _________________ 16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.” |
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Brickwerks Samba Member
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Joined: April 11, 2010 Posts: 214 Location: West Yorkshire - UK
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Posted: Mon Dec 16, 2013 2:27 pm Post subject: |
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Tut tut, lacking attention to detail, switched earth for courtesy lights is brown with a white trace not black, black is ignition live, coh, don't you know your din standards?
![Laughing](images/smiles/icon_lol.gif) _________________
whynotvw wrote: |
I see you wanna start some shit. whats your fuckin probelm? your selling your measly shitty products. bloody brit |
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