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87 Westy Syncro TDI conversion and restoration~lots of pics
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Steve M.
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PostPosted: Fri Jul 29, 2016 7:00 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Looking at your rear skid plates nicely done by you.
I don't know if you have plans for the front so that the suspension/differential frame doesn't hang up on a rock.
I've seen a lot of the front skid plates go from the front bumper to center on the lowest portion of the frame leaving the two radius rods end frames just exposed to catch anything of opportunity.
Here's a pic of the front skid plate on mine just to show you another idea for a skid plate design (as if you do not have enough to do!)
The skid plate I'm fairly sure is factory VW, but I do not know if the skid plate originally went all the way up to the bottom side of the bumper as the P.O. has a winch in there, but I think this gives you better protection of the suspension.
Just f.y.i. for you.
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87vanwes
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PostPosted: Sat Jul 30, 2016 4:01 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Steve M. wrote:
Been thinking the same about door handles and just wondering what is the most durable paint for them.
Powder coating looks great, but is there something out there that is even more durable than powder coat paints or is there one powder coat paint brand more durable than standard paints you find in most powder coating shops?

Your project is looking great by the way, but I think I'm more envious of your shop! (and it's location on an airfield!)


Hey Steve

I don't know what the original finish is made of on the door handles and some of the westy stuff. What I do know is it is some tuff stuff if I had to guess, I would say baked enamel. I don't think there is any thing in a rattle can that would hold up. If your handles are in decent shape I think I would leave them alone. There were many challenges with the powder, it is a high build coating wich interfears with pins, lock cylinders etc and media blasting with aluminum oxide took some time.

The shop is not at the airport I just have a hanger there. I have lots of work waiting on me out there as well.

Cheers
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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 Jul 30, 2016 5:07 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Steve.. I did not see your latest post. Thanks for the pics. I'm going to get mighty creative in that area.

I'm trying to get the updates up to date. I went to the airport and retreaved my pathetic pop top. This thing has seen better days.
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It became an art project for some kids, well I'm hoping it was kids. The black spot was a test by the PO with some fabric paint I'm guessing.
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Doing my best to strip off the original flocking.
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Some paint and clear coat.
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I put on all the moldings while the clear was still some what wet.
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Another thing I should have left alone.
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I wanted to re flock the top. Instead I decided to go with a very light weight carpeting. Back in my boat building days we called it sonitex. If someone needs to know what it's called specifically I will be happy to find out.
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I pre wired the top for 200w of solar and a light up high.
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The lug going through the top will be the positive for the array and the racks themselves will serve as the negative.
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Well now all I need are some friends.... Sad
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This is another mile stone.
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Back on jack stands. It's time for lots of mechanical and electrical before the interior goes back in.
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Cheers
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Kevin


1987 westy syncro tdi conversion and restoration.
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Steve M.
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PostPosted: Sat Jul 30, 2016 5:42 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Looking great! That carpeting came out great on the pop-top. You could do a whole separate thread on that alone.
Surprised you did not add gas struts to help raise the top when you open it.

While your doing interior electronics perhaps think about locations for anti-theft kill switch for ignition or fuel pump, GPS tracker or whatever you want to add to protect the Syncro. It's not like there's score of lowlifes reading the Samba, but you know-your security is your business and you don't have to post it!

Looking forward to your next post! Your skills are an inspiration.
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fleet_maintenance
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PostPosted: Sun Jul 31, 2016 7:50 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

I was coming here to post that it was nice to see the handles getting some attention, and you dropped the update about the top.

Great work, it's refreshing to see what one person can do. I especially like seeing the skill-sets and materials from other vocations bleeding in.

Thanks for the update(s)

Carry on.
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87vanwes
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PostPosted: Sun Aug 07, 2016 4:51 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

fleet_maintenance wrote:
I was coming here to post that it was nice to see the handles getting some attention, and you dropped the update about the top.

Great work, it's refreshing to see what one person can do. I especially like seeing the skill-sets and materials from other vocations bleeding in.

Thanks for the update(s)

Carry on.


Thank you my friend.

It is a bit overwhelming at times, but I guess your right, I have not out sourced any thing, and that's pretty cool. Now on the other hand a true body and paint guy would have been nice Rolling Eyes

It was time to get a coolant system going. The van had never moved more than a couple of hundred feet since the tdi install. This can drive a Person nuts. I chose to plumb the engine just like it was in the gulf. There were a few mods, but it is mostly the same as far as flow.

I drilled and taped for the vanagon specific coolant sensor since I'm using the gage on the factory cluster.
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A little bracketolegy fabrication
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This is the first time I could run the engine for an extended period of time.
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The weather was getting a little ominous. Perhaps the tdi Gods were not ready for me to go on a test drive Shocked
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With the coolant system mostly free of air I mounted the bottle.
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Dealing with crankcase ventilation is important to me for many reasons, so I went over kill.
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I drilled and tapped on the lower right compartment of this photo. This is where the oil from the oil pressure regulator returns access oil to the base pan and wear my filter will drain its oil.
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The scrubbed air is then routed to the post filtered side of the air box.
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It was so cool to finally drive the thing. It was remarkably quiet and vibration free, especially for having no interior. The performance was pretty impressive considering the fuel enrichment was not hooked up. The engine was running somewhat like the ole Eco diesels vw use to offer.

Back at the shop after the drive. The transmission shifted great and was quiet. The reach from 2nd to 3rd was quite noticeable for sure, but the torque of the diesel didn't seam to mind. The true test will be all put back together and loaded.
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It all looks good after my little field trip. No leaks or bad smells. I have a long way to go mechanically and electrically, but I'm quite pleased at the moment Very Happy

This area is great and will get filled up. I have asked a lot out of this limited space, but it looks like I'm going to get it.
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I hope every one is having a great summer. The project has slowed down quite a bit. This is my crazy busy season and I'm thankful for that.

Cheers
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Kevin


1987 westy syncro tdi conversion and restoration.
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Steve M.
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PostPosted: Sun Aug 07, 2016 7:58 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Congratulations on your joyride!

Is that a pair of CAT C12's on the trailer?
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Zeitgeist 13
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PostPosted: Mon Aug 08, 2016 12:14 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

I really like how you're setting up your ALH. Coincidentally I'm also working on the plumbing for my oil catch n' release can on my ALH build, but mine will be the stock unit from a Mercedes. I was thinking about tapping into the turbo oil return line, but I'm intrigued with your use of the filter housing. Do you have any other pics showing the exact location of this port you tapped in there?

I'm also running a Land Rover injection pump, and was wondering what mods you had to make in order to get what looks to be a stock diesel van accelerator cable to work with the LR throttle arm. Did you narrow and drill the end, 'cause it looks like the standard width of the end will interfere with the LR pump housing. My throttle is further complicated by having cruise control, but that's a whole other issue for me to resolve.

Keep up the excellent work!
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87vanwes
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PostPosted: Tue Aug 09, 2016 5:13 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Steve M. wrote:
Congratulations on your joyride!

Is that a pair of CAT C12's on the trailer?


The drive was great.

Those are the new C12.9s @ a 1000hp. There is a lot going on with those things. one turbo feeding another turbo and a supercharger to take out the lag. It was long day taking out a pair of BS home made c18s and putting in those engines.
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Kevin


1987 westy syncro tdi conversion and restoration.
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87vanwes
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PostPosted: Tue Aug 09, 2016 5:36 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Zeitgeist 13 wrote:
I really like how you're setting up your ALH. Coincidentally I'm also working on the plumbing for my oil catch n' release can on my ALH build, but mine will be the stock unit from a Mercedes. I was thinking about tapping into the turbo oil return line, but I'm intrigued with your use of the filter housing. Do you have any other pics showing the exact location of this port you tapped in there?

I'm also running a Land Rover injection pump, and was wondering what mods you had to make in order to get what looks to be a stock diesel van accelerator cable to work with the LR throttle arm. Did you narrow and drill the end, 'cause it looks like the standard width of the end will interfere with the LR pump housing. My throttle is further complicated by having cruise control, but that's a whole other issue for me to resolve.

Keep up the excellent work!


I don't have a pic but I will shoot one. I just barley missed the dipstick tube.

On the pump I used the stock throttle geometry. I changed it at the peddle itself. I will try to go back and find the photo. a little fulcrum change.

https://www.thesamba.com/vw/gallery/pix/medium/1487347.jpg

I don't know how to move photos around..
Hope this helps..
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Kevin


1987 westy syncro tdi conversion and restoration.
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tjet
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PostPosted: Wed Aug 10, 2016 1:19 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Looks great. I really like how you blacked-out the window trim. I'm going to do that on mine too. That ALH fits in there nicely. I look forward on seeing how you will do your engine lid. It looks like a stock lid may clear. I also plan on getting a rover pump for my M-TDI plan (mine is a '97 Jetta AHU that will install @ 50).

What are your new gear ratios?
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ALIKA T3
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PostPosted: Wed Aug 10, 2016 3:53 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Hey man!

I've been catching up on your thread, I was away for 2 months in Europe and now injured at home, so plenty time for the forum Laughing

Your workmanship is always amazing and a pleasure to watch!! My favorite thread so far this year Cool Cool

For the flocking on the roof, a good water pressure washer works wonders Wink

For your solar array negative, I don't understand how you can connect the negative to the module chassis?? + and - both need to be connected to the charge controller no? It's not like a battery negative that you connect to the chassis. Can you explain what your thought is about it, I'm curious Wink

Aloha!
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VanagonPDX
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PostPosted: Wed Aug 10, 2016 4:02 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Beautiful build you have going here!
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Steve M.
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PostPosted: Wed Aug 10, 2016 9:26 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

That paint job looks great out in the sunshine!
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SyncroGhia
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PostPosted: Thu Aug 11, 2016 8:19 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Great work!

Keep it coming Applause

MG
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MidwestDrifter
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PostPosted: Thu Aug 11, 2016 10:59 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

You are a true craftsman, and give yourself too little credit. This project is exemplary and decidedly unique. Thanks for posting. Very Happy
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?Waldo?
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PostPosted: Thu Aug 11, 2016 11:59 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

Looking good.
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PostPosted: Thu Aug 11, 2016 12:05 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

I am interested in what that light weight "sonitex" carpet is called. Do you have a brand or product name? I would appreciate it.
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PostPosted: Thu Aug 11, 2016 12:10 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

jacob. wrote:
I am interested in what that light weight "sonitex" carpet is called. Do you have a brand or product name? I would appreciate it.


It looks similar to Hull Liner fabric/carpet. Basically a carpet without a stiff backing. Vehicle trunk liner fabric is fairly similar.

It molds and cuts easily, so it is ideal for complex curves and tighter radii.
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aaronmjr
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PostPosted: Fri Aug 12, 2016 11:47 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of pics Reply with quote

What a fun read. Thanks so much for sharing.
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