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A Bluestar from Germany...
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offroad.
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PostPosted: Wed Mar 16, 2011 3:34 pm    Post subject: Reply with quote

.


hey mike fancy swapping those wheel for ????










































my soul. lol






















...lee
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SyncroGhia
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PostPosted: Wed Mar 16, 2011 3:58 pm    Post subject: Reply with quote

Laughing

That depends on whether your soul comes with 950 cash Laughing

MG
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BlackDogVan
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PostPosted: Wed Mar 16, 2011 4:21 pm    Post subject: Reply with quote

BTW Jurgen at vanagon.eu had some south african bellhousings listed on his site last time I checked, bolt those 5 cylinders of loverlyness right up!
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SyncroGhia
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PostPosted: Wed Mar 16, 2011 4:22 pm    Post subject: Reply with quote

After the problems I've had with Limey, I don't feel like ever using a Vanagon gearbox ever again!

The 996 gearbox will be more than up to the job, I just wish there was some way I could use one in a Syncro.

MG
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SyncroGhia
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PostPosted: Sat Mar 19, 2011 1:04 pm    Post subject: Reply with quote

I decided to take a few hours today and get the interior sorted on the Bluestar.

I've been meaning to pull the wrong rear seat out ever since I bought the bus and it makes the interior look so much better.

Before (seat needs a damn good clean!)

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Lots of interesting wiring!

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I removed everything, removed the battery, amp but left the Audio leads which run from the front. There was a power cable which ran next to them which has been removed. If I want to add an amp later on, I can and will use the audio leads.

After...

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The carpet is still wrong and I'll be changing that later.

I took the opportunity to remove some of the window tint...

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I do like the idea of having a subtle tint but I'll probably have a company do it so it got the best finish. This stuff just pealed off with a little heat.

I also removed the 240v system, heater and thermostat along with the wiring. There are a few holes to plug which is unfortunate but I'll find some grey plugs which won't be too obvious.

MG
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SyncroGhia
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PostPosted: Sun Mar 20, 2011 12:04 pm    Post subject: Reply with quote

A good friend donated his old 2WD speedo for the Bluestar project.

After a careful dismantle and clean, it's ready to go in.

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I'm hoping that the KM one presently fitted still has the speed sensor for the Cruise Control...

MG
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SyncroGhia
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PostPosted: Sun Mar 20, 2011 2:08 pm    Post subject: Reply with quote

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The overall milage of the van looks to be close to 400,000 Kilometers (around 250,000 miles) and it's had the speedometer replaced (documented). For my purposes, it's easier to start at zero from it's first time in UK and go from there.

Pulling the instrument binacle off I found some interesting wiring!

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It looks like either some parts of the wiring have been replaced and/or someone has been adding a buzzer to tell you that you've left your lights on! I've removed it for the moment as it wasn't connected but I may re-install it later.

The speed sensor is there Smile even if it is only held in with one screw. I just happened to have the correct screw to fit and with a quick clean up, a new illumination bulb. It's all back in but now in MPH.

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The speed sensor wasn't connected so this would be a fairly good reason as to why the cruise control didn't work on the test drive. It's never that simple but here's hoping it'll work on the next test drive!

I think it's time I tackled the fuel and coolant leaks. I've found my spare syncro thermostat housing so it's just a case of swapping them over ha ha!! Rolling Eyes

MG
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SyncroGhia
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PostPosted: Mon Mar 28, 2011 2:38 pm    Post subject: Reply with quote

More work on the Bluestar...

I've pulled the thermostat housing off and replaced it with the Syncro version (aluminium) as I had one spare. It'll last a lot longer than the plastic one! Thankfully, someone had put lubricant on the bolts so everything came undone as it should. There was even a fresh VW thermostat in there too!

While the back end is up on ramps, I've decided to bolt the Porsche rims on (with adaptors) and will take some more photos when I've got the front wheels on. After removing the Tristar front wheel, I realised that I didn't have any stock steel 2WD front wheel bolts to hold the adaptors on with. Will grab some from a friend who breaks vans locally. The wheels really change the look of the van, plus the sliding door now opens past the wheel/tyre without catching but is very close at around 3-4mm. The wheels are 18X8 ET50 with 235/40/18s at the back and 18X7.5 ET50 with 225/40/18s up front.

I also fixed the fuel leaks (nice new fuel filter) and took the opportunity to fix the dead fuel pump mounts. It now runs without leaking fuel everywhere.

While the front end was up in the air, I dropped the spare wheel carrier down to look at the Webasto in more detail. It turns out that it's a water heater Very Happy . I'll be re-plumbing it in at the back in the engine bay where it should be but I'll need the solenoid valves and brackets to make it all fit etc. Does anyone have any close up photos of the factory Webasto fitment etc?

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I need a new coolant expansion cap as the present one doesn't hold pressure but once replaced, I'm hoping to have the van up to temps and have the fan cutting in and out etc.

Unfortunately while I was underneath the front, it became obvious that the front suspension lower arm bushes are dead. The left side lower arm is hard up against the mount point. I already knew that the radius rod bushes were dead and was wondering how to relace them without dropping the lower arms off but now it looks like I'll have to do that anyway. I think powerflex bushes may be used here.

More as it happens...

MG
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OddN
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PostPosted: Mon Mar 28, 2011 3:11 pm    Post subject: Reply with quote

For the BBW46, this is a good place to start:


http://www.telusplanet.net/public/gary2a/rack/bbw46/BBW46.htm

But it was originally only available in syncros, so it might be a little tight, especially with the AC-compressor.


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SyncroGhia
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PostPosted: Mon Mar 28, 2011 3:15 pm    Post subject: Reply with quote

Great thanks. I've seen a setup on a top of the range syncro a while ago which had both air con and Webasto so I know it'll fit but it will definitely be tight.

MG
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ThorAlex
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PostPosted: Mon Mar 28, 2011 5:01 pm    Post subject: Reply with quote

How about fitting it over the gearbox (were the syncro tank is)? lots of room there, but access might be tight
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SyncroGhia
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PostPosted: Mon Mar 28, 2011 11:11 pm    Post subject: Reply with quote

Good idea, however I'm keeping that space free in case I need to use it for a syncro fuel tank when the 996 4WD goes in. I'm hoping to be able to modify the stock 2WD tank and keep it where it is but I won't know until I try.

MG
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OddN
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PostPosted: Tue Mar 29, 2011 1:33 am    Post subject: Reply with quote

To find the parts to install the heater in its original place, you could look to Sweden, as this was a fairly commom option on syncros there. Last summer I was in Lycksele (a small town in northern Sweden) and in the local junkyard there were at least four syncros, all with this heater.
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SyncroGhia
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PostPosted: Thu Mar 31, 2011 11:02 am    Post subject: Reply with quote

Small update...

Sometimes there's an odd reminder that it's better to do things when you have enough time, not rushing around and in daylight...

One look at the thermostat housing top and I realised that I'd messed up by managing to trap the seal Embarassed . One new seal later and we're all back together although I will say that whoever designed the Air-con pipe to run right over the left hand bolts needs a kicking!!

So the cooling system is back together, I have a new cap coming from VW along with some other bits needed. While the expansion tank was empty, I took the opportunity to remove and clean the water level sensor as despite there always being water there, the light was flashing on the dash. Now the light stays out!

Onto the next...

MG
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Last edited by SyncroGhia on Fri Apr 01, 2011 2:37 pm; edited 1 time in total
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SyncroGhia
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PostPosted: Fri Apr 01, 2011 2:17 pm    Post subject: Reply with quote

Just a couple of photos of the ABS system as promised...

What you see under the seat...

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Cover removed...

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It looks a little different on Porsche 18s... sorry for the fuzzy photo.

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This is the power steering pipe which is causing all the noise. No sound baffle means mega noisey power steering... it makes more noise than the engine! Hopefully I can figure a way of adding the all important baffle section from another pipe...

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


MG
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syncrosimon
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PostPosted: Fri Apr 01, 2011 5:14 pm    Post subject: Reply with quote

Brilliant Mike, looking forward to more updates.

Simon.
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James 93SLC
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PostPosted: Fri Apr 01, 2011 6:56 pm    Post subject: Reply with quote

SyncroGhia wrote:
Just a couple of photos of the ABS system as promised...

What you see under the seat...


Thanks! That's very interesting to see.

I've wondered about maybe trying to integrate a MkIII Golf ABS system on the Vanagon. One of the trickiest things I'm guessing is mounting wheel speed sensors.
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Zeitgeist 13
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PostPosted: Fri Apr 01, 2011 7:04 pm    Post subject: Reply with quote

James 93SLC wrote:
One of the trickiest things I'm guessing is mounting wheel speed sensors.


Yeah, that's what I'm waiting to see. I think everything else can be swapped in, but if the speed sensors require ABS specific hubs, then the project gets tabled indefinitely.
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James 93SLC
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PostPosted: Fri Apr 01, 2011 8:59 pm    Post subject: Reply with quote

Zeitgeist 13 wrote:
James 93SLC wrote:
One of the trickiest things I'm guessing is mounting wheel speed sensors.


Yeah, that's what I'm waiting to see. I think everything else can be swapped in, but if the speed sensors require ABS specific hubs, then the project gets tabled indefinitely.


I know the front wheels have a slotted disk (reluctor ring) mounted to the hub. It's a separate part and maybe could be adapted. The rears I think have a ring that slips onto the backside of the rotor outside the bearing housing.

I'm getting a VR6 from a MkIII Golf a guy is parting. I might take a closer look.
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SyncroGhia
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PostPosted: Fri Apr 01, 2011 11:55 pm    Post subject: Reply with quote

From what I've seen, the front upright could be machined to take an ABS sensor but then you would need the ABS ring on the back of the disc.

At the back, the sensor sits in the bearing housing and the spacer between the inner and outer bearings is replaced with one with the ABS ring on. The sensor fits into the hub from underneath.

The sensors are still available from VW Classic parts but they're rather expensive!

MG
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