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7 seater Caravelle Syncro to camper
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vik
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PostPosted: Wed Nov 04, 2020 11:31 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

pnwkayaker wrote:
Vik, do you have any more information about the rear bench (manufacturer, how to obtain it, how it was installed) ?

It has the integrated shoulder belts attached to the bench, which will eliminate the need of cutting a slot on the rear cabinet (which the GW instructions ask you to do to use their kit with the rear mounting points).



It is from M1 beds from UK.
Seat itself is mounted trough floor with 4 srews and steel plate under the floor.
Belts are integrated in the structure of the bed itself.

It will be for sale soon, but I don't know how interesting this will be for anyone from US/CA due to shipping cost

Benefits
- no need to cut holes in cabinets
- OK design wise
- can mount a toddler seat without problem

¨Minuses¨
- due to the seat belts I have to always lift the rear cushion when folding the seat (probably will fit T2 as well)
- it is not as wide as westy seat
- it is not using VW mounting points
- it is not as spacious under the bank as westy seat
- in case of many items over the engine the seat retraction might be compromised...

I managed to buy original westy seat (don't ask me how much I paid for it Sad ) and hope to swap them this winter. But it means cutting few cms from the installed cabinets Sad
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pnwkayaker
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PostPosted: Wed Nov 04, 2020 11:57 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Thanks for the feedback!
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87 Syncro Westy EJ25 ("Tardis")
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vik
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PostPosted: Thu Nov 12, 2020 7:15 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Just a quick update before more stuff is going to happen Wink

Fresh set of Trailmaster +40mm lift springs and shock installed.
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There is never ending debate what combination is best and I did not found any particular reports of these being wrong in any way.
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vik
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PostPosted: Fri Jan 01, 2021 7:12 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Happy new year

First small piece of the puzzle is ¨new¨ instrument cluster. Gone are the analog clock as much as I liked them I really missed the tachometer. I managed to source petrol cluster from unknown year (it turned out it is 86 or older) with minor damage, foil was gone and not working clock (I forgot to get LCD before all closed down).
This time the repair was somehow more hassle than the original one. 3D print to the rescue.
Image may have been reduced in size. Click image to view fullscreen.

It looks, well stock Very Happy
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Foil was replaced by Slowbridge kit. Kai was kind enough to add for me LED for my check engine light.
Best on all of this is that these older tachometers work directly with the Subaru ECU signal so no need for converters or modifying the PCB.

BTW: What was the green light located in the left upper corner originally for?
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4Gears4Tires
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PostPosted: Fri Jan 01, 2021 7:28 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Blinkers
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vik
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PostPosted: Mon Jan 11, 2021 3:59 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

I managed somehow to finish the cut of the travel movie.


Link


Hope you will like it as I see a lot of space for improvements.
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vik
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PostPosted: Tue Apr 27, 2021 8:46 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Well, the the good news is that new drivetrain is ready to be installed in my Syncro. The bad news is that still it will take a while.
Image may have been reduced in size. Click image to view fullscreen.

On picture above you can see rebuild front diff with locker (ADH) and refurbished VC.
On the gearbox side the main difference is 4.86 crown and pinion and .74 4th gear. ALL bearings are new (Vantopia) front and rear along few synchro rings and Aluminum bearing plate.
PO managed to knocked off the locker sensor including bit of the Magnesium gearbox case. This was repaired and now I will have working sensor as well Very Happy Powerflex bushes F+R are in place as well.

This all took obviously longer than expected (covid, brexit...) but can not wait to get to down from 4140rpm to 3230rpm (calculated) @120km/h

Electrical department: Due to modifications in the interior (I managed to source Westfalia 2/3 folding seat) which I needed to get again 4 seats capacity in I will need to cut about an inch from the cabinets. When I have seen how ¨professionals¨ made the installation I wanted to cry. No battery cut off switch, no solar cut off switch. All cables were like spaghetti. So I made a drawing of the installation how it shall be done:
Image may have been reduced in size. Click image to view fullscreen.


Engine department:
Heads shall be back this week from rebuild.
I have new crank, pistons +25, rings, oil pump, bearing, STI conrods, head bolts and block bolts.

When all of this is out the fuel tank is on its way out as well to be resealed and to see if there is any corosion on the body there. Just to find VDO fuel level sender is not possible at the moment.

Sometimes I feel like a Sisyphus. Rolling Eyes
I just want to get in the bus and DRIVE it and ENJOY it
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vik
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PostPosted: Thu May 06, 2021 3:40 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

May I ask if anyone has installed the Powerflex from Heritage Collection?
I ordered few bushes and I was expected classic yellow/purple. I'm sure they will be much better than what I do have at the moment. Just asking...

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Powerflex don't provide too much info if they are more or less stiff. I quote:
The Powerflex Heritage Collection of bushes has been chosen specifically for your modern classic vehicle.

Manufactured using modern day materials with properties biased for the road, these dark grey coloured bushes will restore, compliment and improve any collector's car, whilst retaining the same standard appearance of a regular rubber bush.

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vik
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PostPosted: Sat Sep 25, 2021 12:15 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Recently I had lot of bad luck. My block is stuck 6m in a reputable workshop for honing and still not done. I almost already picked it up when trough a friend an offer for new shortblock was delivered to me. The offer was too hard to resist. Heads are already overhauled so I said yes.
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Next week I expect to see it in the back of my bus.
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djkeev Premium Member
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PostPosted: Sat Sep 25, 2021 4:36 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

A new short block is a beautiful thing!

Dave
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vik
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PostPosted: Thu Sep 30, 2021 12:18 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

I can not agree more with that statement.

Heads after the rebuild
Image may have been reduced in size. Click image to view fullscreen.

What I found sad that the donor car had not that high milage, but they had all valve stem seals gone. All valve seats were grinded too.

Head desiign is interesting for me - SOHC, but 16V Very Happy

Another interesting part might be airbox. In US there are several options available. I had cone cotton filter which I hated
- noisy
- it suck in hot air
In Germany there is company Zanzinger motorsport (I found them almost by an accident) and they have stainless steel bottom part of airbox and uses Subaru upper airbox type (there are 3 versions available). All located on common left side as most Subaru conversions. I do have intake to the righ side and want to utilize WBX cold air snorchel so they modified it to fit the airbox up side down. The elbow is 3D print I designed (V1) from ABS. I might add some ribs if needed. But it seems super sturdy.

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