The Zincro Build

[outwesty]

[outwesty]

A lot has happened in the last few months. I decided to move the shop back to the mountains. I got to spend 65 days in the van while getting the new shop space set up. A few people say cool build, but you made it too nice to use now. Not really. The main reason I went with this color is that it does not show pin striping from branches, etc very much. I’ve never had the desire to buy a new car but this is probably as close as I’ll ever get.

I have put heaters just about every place you can in a Vanagon. Under the truck fridge, behind the passenger seat in a box, under the bench, etc but tried something different this time around. If you’ve ever driven a Vanagon all night long through a cold snow storm you may know how hard it is to keep the windshield ice free and thawed. I ended up mounting the Espar d2 between the seats aimed forward. I have two silicone hoses , one 45 deg ( that points directly at windshield) and a 180 that will direct heat to the rear. This van is so well insulated that I haven’t really found the need to aim it towards the back ever. The van is hotter than you can stand it in 10 minutes of it running. I still have to come up with a box to cover it but the isle way seems like an unused area to me and I honestly don’t really notice it is there. I will probably add two cup holders on the top of the box.

[beach_creature]

Great photos of the van in action! Interesting spot for the heater. I’m gonna play around with that. It’s kind of out of the way there.
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84 Westy
1.9TD AAZ
5spd manual with Locking Peloquin TBD

[outwesty]

[beach_creature]

I was wondering about the fuel tank and how to access the underside. Was hoping there was clearance.
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84 Westy
1.9TD AAZ
5spd manual with Locking Peloquin TBD

[Escorial Syncro]

Any updates on this great build? Did you end up re-working the intercooler setup? Thanks
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Joel Lane
1985 Vanagon converted to syncro, ALH TDI, Reimo Primus top with Westy interior
2002 Toyota Tundra 4x4
1974 Honda CL360 Scrambler (for sale!)

[outwesty]

[outwesty]

For winter break we spent a week in Death Valley. We did around 350 miles in the backcountry and ended up making it up and over Mengel pass at the end. Every 4x4 along the way said they highly doubted we would make it. Well, we did and it is some of the most beautiful country in the park. The 4x4 sprinter that was in front of us had to turn back. No way, no how are you getting up this without at least a rear diff lock. Its steep and off camber so wheels are coming off the ground. (its hard to tell how steep it is in the video) The best part is we got to meet up with samba member tschroeder.
He's in a pretty rad vintage slide-in camper now.

Link

[valvecovergasket]

wow

lovely!

the color, the details, all of it. just awesome.

looking forward to seeing the AWIC install as well. those toyota cores are cheap!
curious where you plan to route the lines also?
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MegaSquirt resource - SpitfireEFI.com

gone, but not forgotten: '83 tdi westy - swap thread

[4Gears4Tires]

Beautiful pics and so close to what I want my van to look like when done. I am going for Toyota Sandy Taupe though. Little rough start on that hill climb, but it went well after that. Nice job.

What wheels are these? And tire size please.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[ALIKA T3]

[SlalomVan]

[outwesty]

[outwesty]

[outwesty]

[outwesty]

Spent the weekend getting rid of the adapter plate and clutch set up and installing the syncro diesel tank/ bellhousing. This is in the 165HP / 300 ft lb range. The regular KEP clutch would not have held and the stage 2 held ok but was just too stiff for daily driving ( it actually broke the clutch slave arm in the end) The flywheel is also a bit too light for a TDI. I didn't plan to run this stuff at the beginning of the project but was unable to source a syncro diesel tank at the time.

Installing the TDI splined input shaft to run a South Bend TDI endurance clutch.

Had to make a dust cover for the diesel bell housing to ALH with FAS pan. I was going to have this cut on a water jet but I had to get this off the lift so cut one on the band saw out of some 0.063 aluminum.

I heard a pop from the clutch on the way home from the last death valley trip. you can see here the pivotl broke off. Below is the diesel arm which uses a different slave mount as well.

This is all just mocked up but I'm starting playing with the water intercooler stuff.

All of the intercooler heat exchangers out there are 2-3" thick. This Toyota prius heater exchanger is less than 1.25" thick and costs less than $50. Still trying to figure out how to space the grill out and make it elegant. I hope it dissipates enough heat. The water in these systems doesn't get very hot so I'm thinking it should work. If the two round vertical braces are cut this wouldn't stick out at all but I hate to do that if I don't have to. I really don't want to mount anything underneath with fans if I can help it as well.

[Escorial Syncro]

Great update! Thanks.

Question, did you have to do much clearancing in the diesel bell housing to clear that clutch kit? I have the same setup but it's still in pieces and I'll be using G60 clutch kit with the custom input shaft.

Thanks for mentioning the diesel specific slave bracket, it jogged my memory to dig through my stuff and see if I've got that and the matching slave arm!

Let us know how that clutch feels please.

Thanks
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Joel Lane
1985 Vanagon converted to syncro, ALH TDI, Reimo Primus top with Westy interior
2002 Toyota Tundra 4x4
1974 Honda CL360 Scrambler (for sale!)

[outwesty]

[pjn_wyo]

What size Donaldson is being used on this build? 6” or 7”?

Also eagerly awaiting an update on the Prius heat exchanger’s performance. It would be nice to package up front.

[outwesty]