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Pastis, The Ultimate Subaru Boxer diesel EE20 Vanagon Syncro
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syncrogreg
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PostPosted: Sun Oct 24, 2010 8:33 pm    Post subject: Reply with quote

ALIKA T3 wrote:
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!!


Cool I'm glad that you're asking that!

This will be modified anyway ... here is the basic idea:

Image may have been reduced in size. Click image to view fullscreen.


Sorry for the quality, it's a phone picture
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ALIKA T3
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PostPosted: Sun Oct 24, 2010 8:43 pm    Post subject: Reply with quote

sounds awesome man!!!

Opposite route of mine,but who know,maybe we will hang out somewhere!!

I' m actually doing experiments ,in fact I'm done with the thinking,to cross the Darien gap cheaper:put the westy roof on the side,on a prebuilt pvc rack made with fittings,and on the parking lot,I'll remove springs and shocks to put old welded shocks (no suspension),just to drive it in the container,so it can be less tall than 180cm,cheaper,otherwise you pay by the volume,cubic meters of your van:bummer!it costs more to cross that region than to ship the van from Brazil to USA Crying or Very sad

Bye!

Keep in touch!
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syncrogreg
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PostPosted: Sun Oct 24, 2010 9:10 pm    Post subject: Reply with quote

ALIKA T3 wrote:
sounds awesome man!!!

Opposite route of mine,but who know,maybe we will hang out somewhere!!

I' m actually doing experiments ,in fact I'm done with the thinking,to cross the Darien gap cheaper:put the westy roof on the side,on a prebuilt pvc rack made with fittings,and on the parking lot,I'll remove springs and shocks to put old welded shocks (no suspension),just to drive it in the container,so it can be less tall than 180cm,cheaper,otherwise you pay by the volume,cubic meters of your van:bummer!it costs more to cross that region than to ship the van from Brazil to USA Crying or Very sad

Bye!



Keep in touch!

Cool!
Yes I will be happy to share some road with others Vanagons!!
I just double checked the standart Ocean Freigt containers sizes and the door height is 2.28 cm . So this is what I keep in mind to build my syncro. Lets do some more research and figure it out.

GB
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ALIKA T3
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PostPosted: Sun Oct 24, 2010 9:27 pm    Post subject: Reply with quote

the container size is one thing,what they charge to you is another thing...you have to be smaller than 180cm,like this they charge you like a car.Otherwise it's way more bucks!!

I have a bunch of links on how to do,where to book etc...and ports to avoid in Colombia.
I also have a colombian guy working with my french surf buddy here,he lived by the 2 major ports where they do the freight on the caribbean side.

I also got in touch with another french guy who is on this trip ,maybe at the same time.
He did it with a motorcycle.

There's abunch a website talking about it,and a guy from Denmark recently finished his trip too around the world.

Bye!
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syncrogreg
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PostPosted: Mon Oct 25, 2010 7:49 am    Post subject: Reply with quote

As I've seen multiple decoupler designs on the market, I wanted to group them on a post (most pics from MG, Thanks MG).

THE US DESIGNS

From Gowesty $995:

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Other US designs:

with ball bearing on the actuator:

Image may have been reduced in size. Click image to view fullscreen.


Without ball bearings at all Shocked (similar to Go westy one):

Image may have been reduced in size. Click image to view fullscreen.

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THE GERMAN DESIGNS

From Syncro-services OR Busschmiede :

The kit 470 euros:

Image may have been reduced in size. Click image to view fullscreen.


pre-assembled 695euros:

Image may have been reduced in size. Click image to view fullscreen.


Is also available with a special design on the teeth for easyer engagement... see picture below that compare a stock cone.

Image may have been reduced in size. Click image to view fullscreen.


The one i got is the German made Kit That seems to me the more complete and robust. The needle bearing on the pinion shaft make me feel good as there is a lot of radial constraints in this area. I really like how the parts goes together compared to SOME other design that really have poor quality of machining and tolerancing.


GB
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buspor63
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PostPosted: Mon Oct 25, 2010 2:10 pm    Post subject: Reply with quote

Greg,

How did you decide to order a kit from Europe instead of getting a ready to use one from, say AA Transaxle? The exchange rate plus shipping would come close to canceling any savings, wouldn't it? Does it end up being a "better" part? Is it bolt in or is there machining envolved? Sorry for the tedious questions that you may have already answered, but I'm at the point of ordering one.
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Corwyn Premium Member
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PostPosted: Mon Oct 25, 2010 2:36 pm    Post subject: Reply with quote

Leave the sliding door open, grab a snow shovel, and start filling the van with $...
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syncrogreg
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PostPosted: Tue Oct 26, 2010 9:10 am    Post subject: Reply with quote

buspor63 wrote:
Greg,

How did you decide to order a kit from Europe instead of getting a ready to use one from, say AA Transaxle? The exchange rate plus shipping would come close to canceling any savings, wouldn't it? Does it end up being a "better" part? Is it bolt in or is there machining envolved? Sorry for the tedious questions that you may have already answered, but I'm at the point of ordering one.


Hi,
The decoupler I choose to buy is to me the most robust decoupler on the market. I like the idea that I will assemble it too as i like to machine. the total cost was 900 dollars including a VERY nice solid shaft. I ordered 6 month ago a decoupler from the big website and I was very disappointed of the quality and i had to send it back.

The choice of buying this decoupler is personal, I'm sure some US design works very well. Just make sure that you get what you paid for.

GB
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syncrogreg
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PostPosted: Sun Nov 07, 2010 5:20 pm    Post subject: Reply with quote

I installed the drawer yesterday and welded the swivel plate. I think the drawer from RMW are ok for the price. They have some geometry issues but works fine.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


GB
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syncrogreg
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PostPosted: Sun Nov 07, 2010 5:51 pm    Post subject: Reply with quote

I started to design my bumpers using the one that are avillable on the market but still making my own touch. I wanted to do t hat before I paint the van as the welds and the risk of scratch is high Shocked

Image may have been reduced in size. Click image to view fullscreen.


CAD drawing of the rear one

Image may have been reduced in size. Click image to view fullscreen.


GB


Last edited by syncrogreg on Thu Nov 18, 2010 12:08 am; edited 1 time in total
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BusJunky
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PostPosted: Sun Nov 07, 2010 6:22 pm    Post subject: Reply with quote

Great work Greg. I cant belive you scored a syncro like that and for the record im a welder/fabracator who welds/tacks all the time w/o gloves lol. Gotta keep it flush!! Did you cut that entire top off with a metabo? Also flap discs with a fine grade do wonders at sanding those remaining welds w/o really tearing into the thin gauge steel. This tread is making me wanna find a doner westy for my 84. Thanks for sharing brotha!!
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ALIKA T3
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PostPosted: Sun Nov 07, 2010 6:23 pm    Post subject: Reply with quote

Sweet!! Cool
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syncrogreg
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PostPosted: Tue Nov 09, 2010 9:23 am    Post subject: Reply with quote

RiveraRambler wrote:
Great work Greg. I cant belive you scored a syncro like that and for the record im a welder/fabracator who welds/tacks all the time w/o gloves lol. Gotta keep it flush!! Did you cut that entire top off with a metabo? Also flap discs with a fine grade do wonders at sanding those remaining welds w/o really tearing into the thin gauge steel. This tread is making me wanna find a doner westy for my 84. Thanks for sharing brotha!!


Thanks,

What is a metabo? I cutted the roof with cut off wheel, hammer chisel...
I used flap discs to remove the weld and I agree with you that they do wander!

Tacking with gloves is just inacurate Cool

GB
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ALIKA T3
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PostPosted: Tue Nov 09, 2010 1:11 pm    Post subject: Reply with quote

Metabo is a power tool brand,may be he wanted to say a tool that clips metal?I don't know how to say it in english,but in french it's "grignoteuse":you can cut sheet metal etc....people who work with drywall frames are also using it.

Keep posting Cool
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syncrogreg
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PostPosted: Thu Nov 18, 2010 12:04 am    Post subject: Reply with quote

I got some mild steel tubing, 2.5 in OD .092 wall thickness. Today I bent the 20 degrees angle with a pipe bending machine.
I packed the inside of the tube with sand+water, compacted it and plugged each end with duct tape.

It's hard to start from scratch...

Image may have been reduced in size. Click image to view fullscreen.

I pre-heated the tube with a torch so inner bends stay smooth with no waves. It worked pretty well for now.

Image may have been reduced in size. Click image to view fullscreen.



I tried to bend 90 angles but It does not work well so I will eather do like that : http://www.youtube.com/watch?v=cquCfvsvoq0

Or try to find some 90 elbows and 45 for front bull bar.

Please pm me if you know a place or website that have 90 elbow 2.5 in OD with wall thikness .095 to .125in Thanks

GB
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insyncro
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PostPosted: Thu Nov 18, 2010 9:09 am    Post subject: Reply with quote

Greg
Have you picked an engine yet?
Subaru diesel please.

dylan
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syncrogreg
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PostPosted: Thu Nov 18, 2010 9:14 am    Post subject: Reply with quote

insyncro wrote:
Greg
Have you picked an engine yet?
Subaru diesel please.

dylan


Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know Very Happy

GB
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insyncro
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PostPosted: Thu Nov 18, 2010 11:17 am    Post subject: Reply with quote

syncrogreg wrote:
insyncro wrote:
Greg
Have you picked an engine yet?
Subaru diesel please.

dylan


Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know Very Happy

GB


I know two different fellows making adapters to be able to use the Vanagon steering pump on EG33 and EZ30 motors.
Not super difficult to do.

dylan
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PostPosted: Thu Nov 18, 2010 2:09 pm    Post subject: Reply with quote

syncrogreg wrote:
insyncro wrote:
Greg
Have you picked an engine yet?
Subaru diesel please.

dylan


Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know Very Happy

GB


What criteria are you using to choose the engine for your ultimate expedition syncro?

Awesome progress so far BTW, we've been without a killer build thread for too long!!
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syncrogreg
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PostPosted: Mon Nov 22, 2010 10:51 am    Post subject: Reply with quote

BlackDogVan wrote:
syncrogreg wrote:
insyncro wrote:
Greg
Have you picked an engine yet?
Subaru diesel please.

dylan


Not yet, I'm right in the midle of choosing between subaru diesel CR or tdi CR.

The Sub does not have the steering pump as all the diesel model are equiped with electric steering units... So if I go this way I will have to fit a steering pump somewhere but it should be fine.
I'm just going to call now a junk yard !!

I'll let you know Very Happy

GB


What criteria are you using to choose the engine for your ultimate expedition syncro?

Awesome progress so far BTW, we've been without a killer build thread for too long!!


Thanks!

I considered respectively : swap that was never done before, price, common rail diesel, weight, Ground clearance, lid clearance, efficiency and part availlability.

Part availlability in last because i hope I will end up with the subaru diesel Laughing

It's hard to answer that question as VW Vs Sub as different pro and cons that compensate each other. The subaru diesel is definitly the best one to me but pricy Sad

GB
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