Oregon Trail Syncro build

[dkoesyncro]

After returning from solstice and going over OTiS with scrutiny, hoses were a "to-do". Amongst juggling different parts of this project and also "simplifying" any potential future disaster, I built coolant pipes! I used to have "this and that" and I began to forget what the donor hose was from.

All I need for spares are straight couplers and a some 90 bends, simple...
Tubes are painted and drying.

[Sodo]

keep at it brother. Routing those pipes to clear other components with style - you are doing a beautiful thing.
_________________


'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

[dkoesyncro]

The tubes are painted and installed. I'm really glad I did this, it cleaned up the bay and made hose replacement simple.

I've been tossing around intercoolers a lot, mostly reading in the evening. When it comes to what's best tube and fin vs. bar and plate , that will always be a debate. Driving type and location dictate this choice and another, bar and plate are easier to build and cheaper to produce...I had a Renault tube and fin, Saab bar and plate and a VW tube and fin. I chose to modify the VW. After processing my intercooler knowledge this intercooler has the best exchange and although busy pressure loss isn't something I'm concerned about. I'm running 3.5 feet of boost pipe. With 360° of bends.

I rebuilt the D pillar to facilitate future plans, almost finished. I have other welding to do before seam sealing.

More to come!

[dkoesyncro]

[dkoesyncro]

We're getting closer, I was hopeful that I was going to light her off today but... maybe tomorrow or the next day, we're close though!

All seam sealed

Intercooler prepped

Looking down the D pillar

Oil cooler shrouded below the snorkel

Oil pan and windage tray/baffle mod, keeping oil at the pump, always!

[dkoesyncro]

And a sneak peek,

[dkoesyncro]

All this talking about scoops motivated me.

it's roughed in, skim coated this evening. We'll be sanding in the morning.

[Scott@USRT]

Good to see that you're putting the USRT V-WALK manifold to work. I've got mine flipped upside down for a top mount configuration. Mk3 AHU TDI powah!

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[Steve Arndt]

[dkoesyncro]

I believe it's a wahler, I got it from an 80/90s vintage Volvo found in the wrecking yards.

[dkoesyncro]

It's been a while since I have added anything...

I've been here and there on the forum but I thought I'd bring my van OTiS back up!

We have had a lot of fun and adventures. This has led up to some changes. I've wanted to have an "oem like" turbo system. I looked at the aeb 1.8T and realized this early system will work. I have to first figure out the hall sender/cam position sensor. The ABA was replaced with the AEG and with it came the newer ignition system. This ignition could easily integrate and run the 1.8T management. More work was needed however pretty straight forward, armed with both schematics (aeb/aeg) I eliminated the CIPs and will be using wasted spark coil pack.

[dkoesyncro]

While the trans is out being rebuilt/engineered. I made some progress.

I have the AEB wiring installed, I have to make another trip to the wrecker for an AWM "coil on plug" harness. Waiting for the turbo housing to come back from the machinist, were adding timecerts and going with studs. The bolts really got siezed in and galled up. The manifold and turbo housing will head off to the ceramic coater once the housing is back in hand.

I'm feeling good about this go around!

[dkoesyncro]

While the trans is out, I got the lump buttoned up and looking quite cool imo! The engine bay is ready, made a custom Ford focus airbox and snorkel (oem style this time). We added LS truck coils for the ignition. I got a great deal on 2/0 marine battery cable, out with the old battery cable. Lots of messes and lots of ideas and projects to come. All the wiring is done and wrapped, well 90% anyways!

[uberaudi]

Great build man! Where did you find all the aluminum bends for your coolant hardlines? Will you be flaring the ends to prevent slippage?

Also, you still rocking the franken Volvo thermostat housing?

Keep up the excellent work!

[dkoesyncro]

The bends are from either Columbia River Mandrel or GBE Mandrel, I used an improvised vice grip bead roller on the ends. I am still using the Volvo oil cooler, I get an extra qt+ capacity with it!

[Zeitgeist 13]

What did you end up doing about the cam position sensor?
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[uberaudi]

[dkoesyncro]

[dkoesyncro]

[vwhammer]