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Pastis, The Ultimate Subaru Boxer diesel EE20 Vanagon Syncro
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syncrogreg
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PostPosted: Mon Oct 04, 2010 7:04 pm    Post subject: Reply with quote

Thanks Syncroincity,

After a good night of sleep I started the welding.

Spot welding at the factory spots:
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Good structural spot welding all arround the roof:
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Then once the entire roof is spot welded it's Ok to do a continuous weld. This continuous weld needs to be very thin as it is not used for structural purposes but instead is used to fill the metal (cosmetic)
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I did the continuous weld just in the concave corner of the shoulder so it was not too bad to grind and is not very visible.
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GB
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Alaric.H
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PostPosted: Mon Oct 04, 2010 7:46 pm    Post subject: Reply with quote

It is still not to late to put on a high top.
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syncrogreg
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PostPosted: Mon Oct 04, 2010 9:11 pm    Post subject: Reply with quote

Alaric.H wrote:
It is still not to late to put on a high top.


Hi,
I had a 1.6TD 5 speed high top that I restored 6 years ago in france. I took it on long trips in Europe. I can tell what are pros and cons.
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PROS:
1/ once you pull the curtains nobody can tell if you're in or not. I did spend three days in the midle of Barcelona (SPAIN) with one buddy sleeping in the top and two sleeping on the bottom, cooking,partying ...
2/Storage is very good, I always had scoubadiving stuff, extras pillows,blankets...

CONS:
1/ Make the center of gravity higher then affect the driving considerably. A litle boat feeling...
2/ height constrain (travel with containers..) at least in europe where you have height limits everywhere: beach, villages, parking...
3/ Wind sensitive and less fuel efficient.

I think This time i will go Pop Top as I already have it Wink

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Pop Top fit just right, attach with no difficulty to the rear bracket and close straight allined with the front over head rack.

GB


Last edited by syncrogreg on Mon Oct 04, 2010 9:16 pm; edited 1 time in total
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IdahoDoug
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PostPosted: Mon Oct 04, 2010 9:15 pm    Post subject: Reply with quote

I'm impressed. In the time it will take you to convert a hardtop Syncro into a camper, I will have merely gone through the mechanicals on my hardtop. Nice work - keep it up.

DougM
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syncrodoka
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PostPosted: Mon Oct 04, 2010 9:20 pm    Post subject: Reply with quote

This can't be in real time. Confused
syncrogreg cut off the roof section, tacked it back into place, welded and installed the top in a day? If it is really that easy I'm gonna start looking for a westy donor right now- seriously. Shocked
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IdahoDoug
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PostPosted: Mon Oct 04, 2010 9:25 pm    Post subject: Reply with quote

Snicker. Agree but it sure is inspiring me. Not that I'm going to be cutting up my own beast like his. I'd rather spend less money on one of those European rooftop Autohome crank up tents with the added benefit that I can use it on any of our vehicles, plus I won't have to haul that added weight around for the 50 weeks a year it's a daily driver. Great project to watch.

DougM
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syncrogreg
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PostPosted: Mon Oct 04, 2010 9:29 pm    Post subject: Reply with quote

syncrodoka wrote:
This can't be in real time. Confused
syncrogreg cut off the roof section, tacked it back into place, welded and installed the top in a day? If it is really that easy I'm gonna start looking for a westy donor right now- seriously. Shocked


This is not in real time!! It took me a good three weeks of work to do that. I'm picking my picture from my other blog that I'm abandoning. because the Samba is just the best way to show a project. I'm just catching up all the pics I have to post!
Right now what I have in my garage is the van less doors, trunk, engine trany assembly, gas tank, It's pretty much bare metal soon ready for the PRIMER!!
At this speed posting the pics, I should be back to REAL TIME in two days.

I hope you're not disapointed Wink

The welding wave *
I had to fix the couple spot of rust that was on the bottom of the windshield.

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I used the Westy nose to cut the pieces I needed, It was surprisingly very clean.
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I know that I should wear gloves but sometime sacrifice for better result is worth it.
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BOOM DONE 5mn.... I'm just kiding Very Happy
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GB


Last edited by syncrogreg on Mon Oct 04, 2010 10:47 pm; edited 2 times in total
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Sir Sam
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PostPosted: Mon Oct 04, 2010 10:14 pm    Post subject: Reply with quote

While you have the interior gutted consider doing some sound deadening. I put in several coats of a spray in sound deadener in my cargo area and it makes the rear of the van VERY quiet going down the road.

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This is the product I bought, thick, sprays on, ends up being cheaper and lighter than dynamat like products, but does take several applications to build up the thickness to the point where its the same. I cannot speak to the amount of time required for either.
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More and more coats applied(the right side is the latest coat, still kinda wet and shiny)
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Just doing a "knock test" between my syncro(7 pass) and this one over by the galley, the sound deadened one is significantly better, sounds much more solid, and not nearly so tinny.

I then covered the edge by the door with truck bed liner for added durability:
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I know its kinda hard to see because its dark, but it gives a nice texture in the sound deadening and then a little bit more of a gritty texture from the truck bed liner.

Are you doing the westy interior as well?

Have fun with the swap, I "finished"(they are never really done) mine up almost exactly a year ago. Been to alaska and back now with it.
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syncrogreg
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PostPosted: Mon Oct 04, 2010 11:28 pm    Post subject: Reply with quote

Sir Sam wrote:
Are you doing the westy interior as well?

Hi,
Your spray looks cool and easy to apply in the hard access corners!
Good Job!
Yes, I plan to use the brown interior that was in the 84 but it's not going to match the 89 bluestar seats (2front,2jumps,rear bench) that I have Crying or Very sad Anyway my girlfriend want to paint them so for this matter it's better.

Here is what I've done for the insulation: 100sq.ft MEGAMAT roll


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All the left side panel and the trunk

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As well as the front boxes that generate a lot of noise.Thoses are double layer

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I still have to finish the front and the right side. Maybe tomorrow Very Happy ?

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GB
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jabba
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PostPosted: Sun Oct 10, 2010 2:51 am    Post subject: Reply with quote

Hi Greg,
Very nice job on the Syncro (you have done a nice deal with the 2 bus).
I've read your engine project for this bus, and want to tell you, i've ever seen a 2,0l tdi CR in a vanagon with a 50 angle. It was the project of Erik the guy i'm spoken about (with the black highroof) in my thread. Wink
6 years ago you were living in France and drive a diesel popo Laughing why don't you register on T3zone.com?
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insyncro
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PostPosted: Sun Oct 10, 2010 6:01 am    Post subject: Reply with quote

I am very happy to see others using a sprayable sound deadener.
I have used many different types and really prefer to spray multiple layers of sound deadener, thermal barrier and cavity wax. Truck bed liner works well too.

dylan
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Last edited by insyncro on Sat Dec 04, 2010 7:11 pm; edited 1 time in total
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syncrogreg
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PostPosted: Mon Oct 11, 2010 3:31 pm    Post subject: Reply with quote

jabba wrote:
Hi Greg,
Very nice job on the Syncro (you have done a nice deal with the 2 bus).
I've read your engine project for this bus, and want to tell you, i've ever seen a 2,0l tdi CR in a vanagon with a 50 angle. It was the project of Erik the guy i'm spoken about (with the black highroof) in my thread. Wink
6 years ago you were living in France and drive a diesel popo Laughing why don't you register on T3zone.com?


Thanks,

I think I was not used to internet at this time. i'm from a little town and did all the restoration locally, BUT now I understand how much easier it is to have a big network of help I should have done that !!

Ca t'as pas plus le Tennessee?

GB
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jabba
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PostPosted: Thu Oct 14, 2010 1:11 pm    Post subject: Reply with quote

Salut Greg,
Unfortunatly, i've never been in Tennessee... Wink
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syncrogreg
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PostPosted: Thu Oct 14, 2010 2:50 pm    Post subject: Reply with quote

jabba wrote:
Salut Greg,
Unfortunatly, i've never been in Tennessee... Wink
Well.. You're welcome to visit me sometime. Hopefully the syncro will be ready to do some excursion in the smoky mountains Wink

GB
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syncrogreg
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PostPosted: Tue Oct 19, 2010 7:27 pm    Post subject: Reply with quote

Today is a great day.

I just received my decoupler kit. It's from Syncro-services.com , It's really good quality, the parts are well machined and the tolerancing make sense.

Here is the picture of the kit.

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GB
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buspor63
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PostPosted: Tue Oct 19, 2010 8:07 pm    Post subject: Reply with quote

Oooh, very nice. I think thats the thing I will buy next. I'm not brave enough for the kit though, I'll have to go with the complete version.
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ALIKA T3
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PostPosted: Tue Oct 19, 2010 9:50 pm    Post subject: Reply with quote

Good work on this van Shocked

Looks super clean!!

I was going to ask you if you were on T3zone also,but Jabba did it first Wink

Where do you plan to go around the world?

I'm doing the road from Seattle to Chile within the next 2 years if everything goes well Wink

Bye!!
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HeftySmurf
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PostPosted: Tue Oct 19, 2010 11:36 pm    Post subject: Reply with quote

Very nice work! Applause
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PostPosted: Wed Oct 20, 2010 2:05 pm    Post subject: Reply with quote

awesome work! on the first page, one of the pics looks like you installed a garage door opener in the van. opticallusion
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Marty Mcfly
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PostPosted: Wed Oct 20, 2010 8:28 pm    Post subject: Reply with quote

Great work! I'll be watching this for sure. Planing a very similar course for my '86 synco that I found on craigslist for $900. Then picking up a free westy this week! Mines in ruff shape but seeing this has motivated me... keep it up.
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