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87 Westy Syncro TDI conversion and restoration~lots of pics
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Multiman mv
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PostPosted: Wed Sep 12, 2018 3:48 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Also wishing you and your family safe days ahead. Hopefully for your sake the storm will make landfall further south of where you are. In any event, it looks like an awful amount of rain is headed your way. Maybe a good reason to load up that syncro and head inland for a little trip? Good luck and keep us posted.
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87vanwes
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PostPosted: Thu Sep 13, 2018 5:40 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Thanks guys
We're in good shape here. I'm thinking we will get a prolonged blow from the east going to the southeast. My best guess would be winds in the 50 mph range with a good amount of rain. We're not prone any kind of flooding due to rain. Wind driven flooding is another story but east winds won't do it.

I will do an update soon and keep you posted on any storm problems.

Once again thanks for the thoughts and well wishes you guys are great

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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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big swifty
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PostPosted: Thu Jun 20, 2019 4:34 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Resurrecting this beautiful build thread. Working on my exhaust for my van. Would you kindly post some pics of your exhaust system?
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Evan
1987 Vanagon Syncro // Westfalia pop-top graft // Factory new ALH. 11mm IP. AFN 110 RC 2,3,4 // S7 turbo// Titan P502's
2013 Golf 4d TDI. No mods. Yet.
[1991 Jetta coupe TD. Giles Superpump. Custom tall 5 speed. SOLD
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[email protected]
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PostPosted: Fri Jun 21, 2019 4:01 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

yes more please!!!!
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87vanwes
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PostPosted: Sat Jun 22, 2019 3:41 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

big swifty wrote:
Resurrecting this beautiful build thread. Working on my exhaust for my van. Would you kindly post some pics of your exhaust system?


Hey swifty
When I did my exhaust I was hoping there was a kit available but no luck finding one. Earlier in the thread I showed an exhaust using the factory tdi resonator. It did not last very long before it spit it’s guts out and never was as quiet as I would have liked.
In the end I wound up using the stainless Moroso muffler. It’s fairly quiet and small. You may have noticed I relocated the turbo actuator to keep the exhaust tucked in tight to the engine. The exhaust is completely attached to the engine. I’ve thought of adding an additional brace to the bell housing, but so far so good.

Here are some pics for you.
I hope this helps.
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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87vanwes
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PostPosted: Sat Jun 22, 2019 4:10 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

[email protected] wrote:
yes more please!!!!


I guess this is the latest.

On the last page I shared the plugin ac idea using a household compressor tied into the onboard ac system. It was a learning experience and almost worked. The compressor simply could not produce the volume of refrigerant for an expansion valve system.

Another problem was the vw radiator fan was loud and was a power hog. The mod I did for this was to use a fan and motor out of a mark 3 tdi car.

I cut an adaptor to fit the fan and motor into the Vanagon shroud. It is very quiet and uses very little energy.

A few words of caution the ALH TDI has a very low heat signature meaning it’s very easy to cool and puts very little strain on the cooling system. I’m not sure this fan mod would keep up with the factory engine or other repowers.



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14 years apart and the wire colors are the same go figure.
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I will try to get the AC part up soon.
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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87vanwes
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PostPosted: Sat Jun 22, 2019 4:54 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Ok... the plugin AC puzzle.

Google was no help on tying two compressors into one system. Lots of hybrid car stuff but no luck on my quest. The idea was to use the existing ac equipment already in the van with a 120v compressor piggybacked with the engine driven one.

I decided if I were going to pull this off was to use belt driven automotive compressor. The question was how much horsepower would it take. Google was all over the place, five horsepower, ten horsepower... this was not doable. I decided to go out on a limb with 3/4 horsepower. If I can’t stay well under 20 amps I’m out of business for plugging in.

So I bought a sanden compressor.
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Used the specs and cut out a bracket to link a standard motor to the compressor.
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I also picked up a waterproof 3/4 horsepower motor and this was the test.
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This is with an onboard battery charger that keeps up with all the fans.

A few more pics of the setup working well.
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The battery charger is under the rear cabinet this one is separate from the house charger. It is easily removed if a charger is needed.
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Another cool one is cruise control Cool
It’s the go Westy with a factory stalk I scored on eBay
After a little adjusting it works quite well
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I hope every one is well and thanks as always for the thoughts and kind words.
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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big swifty
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PostPosted: Sun Jun 23, 2019 12:57 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Thank you for the pics Kevin.
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Evan
1987 Vanagon Syncro // Westfalia pop-top graft // Factory new ALH. 11mm IP. AFN 110 RC 2,3,4 // S7 turbo// Titan P502's
2013 Golf 4d TDI. No mods. Yet.
[1991 Jetta coupe TD. Giles Superpump. Custom tall 5 speed. SOLD
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ALIKA T3
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PostPosted: Mon Jun 24, 2019 12:44 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Wow Kevin! This a great job as usual, looks well designed as usual Cool Cool
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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?Waldo?
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PostPosted: Mon Jun 24, 2019 2:34 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Fantastic!
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puchfinnland
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PostPosted: Sun Jul 07, 2019 5:50 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Great work as usual, so 2 belt driven compressors on one system.
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87vanwes
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PostPosted: Wed Jul 31, 2019 4:57 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

ALIKA T3 wrote:
Wow Kevin! This a great job as usual, looks well designed as usual Cool Cool


Thanks ALIKA
Hope all is well with you. Is the address you gave me years ago still good?
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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87vanwes
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PostPosted: Wed Jul 31, 2019 4:59 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

?Waldo? wrote:
Fantastic!


Thanks Andrew.

I need to pick you genius diesel mind sometime.
How are your projects coming along?
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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87vanwes
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PostPosted: Wed Jul 31, 2019 5:03 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

puchfinnland wrote:
Great work as usual, so 2 belt driven compressors on one system.


So far so good. The only thing that worries me is oil starvation with two compressors. The oil could pool at the non running one. They are at the same elivation so maybe not.
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Kevin


1987 westy syncro tdi conversion and restoration.
http://www.thesamba.com/vw/forum/viewtopic.php?t=6...highlight=
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fleet_maintenance
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PostPosted: Sat Dec 07, 2019 2:27 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

This thread just turned 4 years old!?! Time flies, how is the van working out for you? (and happy holidays!)
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ALIKA T3
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PostPosted: Thu Jan 23, 2020 8:38 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

87vanwes wrote:
ALIKA T3 wrote:
Wow Kevin! This a great job as usual, looks well designed as usual Cool Cool


Thanks ALIKA
Hope all is well with you. Is the address you gave me years ago still good?


Oh I just see this now as I am looking at your mods again!

Yes it is Smile

I just got the plates you sent me welded for the Syncro conversion a few months ago, been doing some short test drives the last couple weeks to sort out everything!
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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jrcstudios
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PostPosted: Wed Apr 22, 2020 7:39 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

I knew I couldn't be the only one that wanted to use the factory AC as a "plug in"! I would love more details on this, I'm about to try the same thing on a '91 tin-top with the tunnel AC (which works great on the engine) Are the compressors simply parallel in plumbing? or do you have change over valves?
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tilstad
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PostPosted: Sun Jul 26, 2020 5:05 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Could you post some results of the AC system? Is it working satisfactory? Pro's/Cons?

Was it a 120V motor?
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tilstad
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PostPosted: Tue Jan 19, 2021 11:24 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Any news on how the ac worked? Id love a similar setup myself. We get roasted here in Texas.
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Syncrodelic
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PostPosted: Wed Oct 13, 2021 8:58 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Congrats on this amazing build Kevin. So well done, and so well documented. Like many others, I really appreciate the efforts to share your knowledge and progress.

I really like the system you designed to mount the TDI and I had decided to copy it for my own TDI install. However something struck me when I woke up recently thinking about it. Your engine/transaxle package is mounted at 3 points I believe--at the two trans mounts at one end, and at the other end on a single mount at the far end of the engine. What is making me hesitate is that generally the engine end is mounted with two arms coming from the sides of the motor somewhere in the middle of the block. Having the single mount at the end moves the support farther out from the center mass of the block. Does having the engine/trans mounted at each far end put a lot of stress on the bellhousing? With the bellhousing right in the middle, it seems like there would be a lot of strain on those bolts and the housing itself. I know that this is how the ALH is setup on the MK4, however the motor/trans is a much longer package on the Syncro. I see that it obviously works for you, but I'm concerned about rough offroading, which I do like to do in my Syncro. Do you have any concerns there?
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