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Hawai'ian Magnum Syncro M-Tdi
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ALIKA T3
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Posts: 3513
Location: Honolulu,Hawaii and France
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PostPosted: Wed Jul 11, 2012 10:45 pm    Post subject: Reply with quote

Weird,I didn't receive notice of answers.... I hope you get it sorted out Smile

I dropped a ton of parts to powder coating recently,everything under the van basically Shocked

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got them back today,minus the subframe for the front suspension and differential,they missed a few spots Confused

Got the front syncro hubs sleeved for centering the Eurovan rotors too.
Found a pair of Audi 200 Quattro 269x20mm rear rotors ,NOS on ebay,Bradi brand (same as Brembo basically) for less than 60 bucks shipped Cool
For this price,I give up messing around with the Audi V8 rear rotors Rolling Eyes

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every washer and bit has been powder coated,tank straps too

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I can't wait to assemble all the bits with new bushings and all,I feel like assembly and brand new toy Razz

Oh,wait,it is a brand new toy Twisted Evil
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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syncrogreg
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PostPosted: Wed Jul 11, 2012 10:58 pm    Post subject: Reply with quote

I'm jealous! Is it expensive?

Gsb
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ALIKA T3
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PostPosted: Wed Jul 11, 2012 11:04 pm    Post subject: Reply with quote

1500 for everything I could drop.

It was way cheaper in France ,but they did a good job.

95 bucks a rim,hell,it cost me 60 for 4 in 2008 Rolling Eyes
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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insyncro
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PostPosted: Thu Jul 12, 2012 5:39 am    Post subject: Reply with quote

Looks good Exclamation
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Franklinstower
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PostPosted: Thu Jul 12, 2012 10:21 am    Post subject: Reply with quote

ALIKA T3 wrote:
Found a pair of Audi 200 Quattro 269x20mm rear rotors ,NOS on ebay,Bradi brand (same as Brembo basically) for less than 60 bucks shipped Cool
For this price,I give up messing around with the Audi V8 rear rotors Rolling Eyes



Alex,
What calipers are you going to use with the audi 200 rotors?

Paul
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ALIKA T3
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PostPosted: Thu Jul 12, 2012 10:09 pm    Post subject: Reply with quote

Thanks insyncro Cool

Hi Paul!

I have VW Passat calipers,mounted originally with the same dimension rotors: 269x20.Don't ask me the model,I can't remember.... I dug a lot on vagcat.com to find them,then bought them used on ebay.


I had to buy a new set of carriers when the machine shop screwed them locally when I tried to fit them with Audi V8 rotors Mad Mad Mad

I hunted down a lot on the casting markings to find compatibilities between caliper carriers Twisted Evil .

I have the thoughts and cross part numbers somewhere on a paper ,I'll put them down the day I will do the job.

That's basically the same kit as everybody else sells.
I got the adapters from Burley,I'll have to modify them for the third time now Rolling Eyes to put them back to original look....

cheers
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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ALIKA T3
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PostPosted: Thu Jul 12, 2012 11:10 pm    Post subject: Reply with quote

Got shit done today after work

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Front and rear control arm urethane bushings from Burleymotorsport.com

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upper control arms with new Febi ball joints and spacer from Burleymotorsport.com

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Upper control arm being assembled Smile
Urethane Powerflex bushings from T3technique.com
Upper ball joint spacer form Burleymotorsport.com (now sold by GoWesty.com)
febi ball joints

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Upper control arm being assembled Smile
I used a 1-1/4" brass fitting under the control arm bore because the sleeve sticks out on the other side....

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Upper control arm assembled Smile
Old bushings shown

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Pressing in the new Febi lower ball joint with a 2" pipe

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_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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insyncro
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PostPosted: Fri Jul 13, 2012 9:52 am    Post subject: Reply with quote

The new suspension will feel sooo good.
And look pretty darn good too.
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ALIKA T3
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PostPosted: Fri Jul 13, 2012 10:22 am    Post subject: Reply with quote

Thanks !

everything is gonna be brand new,bushings,transmission donuts etc....

The VW donuts I received are actually a little bit thinner than the old ones,that bothers me Confused
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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ALIKA T3
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PostPosted: Tue Jul 17, 2012 11:19 pm    Post subject: Reply with quote

I did some paint touch up today and worked on the viscous coupling.

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VW syncro stabilizer links replicas made by Burley Motorsport

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Painted after mounting the balljoints to cover the non painted areas on the ball joint knuckle thingy

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Touched up the front spindles

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and rear hub as well Smile
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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insyncro
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PostPosted: Wed Jul 18, 2012 5:14 am    Post subject: Reply with quote

Very detailed Alika.
Impressive Exclamation
Your Syncro is going to be awesome.

Keep up the good work.
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ALIKA T3
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PostPosted: Wed Jul 18, 2012 11:04 am    Post subject: Reply with quote

Thank you,much appreciated coming from you Cool
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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insyncro
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PostPosted: Wed Jul 18, 2012 11:11 am    Post subject: Reply with quote

And thank you for posting your progress.
It really is a commitment to do so.
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ALIKA T3
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PostPosted: Sun Sep 16, 2012 1:01 pm    Post subject: Reply with quote

Got back from vacation in France.

Brought back the guts of a syncro transmission parted out a while ago,bought in Germany on ebay for the locker differential to convert my front differential.

My brother in France received the box about a year ago,and shipped me what I needed,now I have extra parts on hands Cool

I received the front wheels adapters from T3technique,I 'm waiting for the correct studs now Wink

I'm about to send on the mainland all the chassis hardware to get them electroplated,like new ,or even better Cool Cool
see topic here for info http://www.thesamba.com/vw/forum/viewtopic.php?t=520051

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I made a close up video of the hardware with comments so I don't end up with a giant puzzle when they get back Twisted Evil Twisted Evil

I also picked up the subframe that was not enough coated in a few spots,they re-did it :

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That's gonna be cherry brah Cool Cool Cool
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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ALIKA T3
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PostPosted: Mon Sep 17, 2012 9:19 pm    Post subject: Reply with quote

I just painted the springs Cool

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_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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Hodakaguy
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PostPosted: Tue Sep 18, 2012 1:19 am    Post subject: Reply with quote

Nice Work!
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Hodakaguy
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thummmper
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PostPosted: Tue Sep 18, 2012 8:36 pm    Post subject: Reply with quote

bravo alika! I will embrace powdercoating on my next one. It seems like a waste of labor to not powdercoat. My rattlecan job isnt worth spit near the ocean.
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insyncro
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PostPosted: Wed Sep 19, 2012 9:49 am    Post subject: Reply with quote

I just disassemble a Syncro front end and will be powder coating it to do some long term testing vs rust encapsulating paints.

Nothing fancy, silver and black for all suspension parts.
Here are the parts after a Hotsy powerwash.
Sandblasting is next on the list.

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.

Thanks for the inspiration Alika Exclamation
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Hodakaguy
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PostPosted: Wed Sep 19, 2012 11:50 am    Post subject: Reply with quote

I've been using powder coating for a while now and found it to hold up really well. Make sure it's a UV stable powder, not all powders are created equal.

Hodakaguy
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ALIKA T3
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PostPosted: Mon Jan 14, 2013 7:03 pm    Post subject: Reply with quote

Alright people,here are the news starting back from last November 2012....

Mid November,I received a notice that the property on which the syncro was staying on is being sold.I gotta move it out from there before January 1st 2013....

All the shit always falls in the same time....
Long story short,hell of a busy season at work for me,I had to re-assemble in a rush the syncro to at least put it on wheels.
That really sucks because I was about to ship the hardware to the mainland for electroplating....stressful situation Evil or Very Mad

Rear wheel seal,genuine VW
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Rear wheel seal ,vitton with double lip on the outside.Needless to say,I mounted the vitton seal Laughing
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VW on top,vitton bottom
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Cleaned up rear wheel hub bolts
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I had to sand down the Porsche 930 style stub axles,they didn't fit in.

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Rear wheel bearings
Inner is FAG Korea (FAG's are Korean? Laughing Laughing Laughing ) and outer is Febi made by INA in Germany Cool
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I pressed the front wheel bearing in the spindle,a 3" PVC sewer pipe does the perfect job to hold the whole thing.
I pressed on using a differential bearing cup from a Vanagon,perfect diameter Razz ,just grinded it down on the outside diameter for an easy removal from the spindle.
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Circlip in place
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A french T3zone member donated to me 2 genuine front VW seals when I was in France Cool ,I ordered the remaining 2 from GoWesty,one of them was a VW seal the other was a DPL brand.
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DPL
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The related discussion about these seals here :
http://www.thesamba.com/vw/forum/viewtopic.php?t=395577&highlight=front+seal

Installing the front wheel studs
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The VW workshop manual is rather retarded on that following point:they make you pressing the hub in the bearing,which is already pressed in the spindle,rather than making you pressing the wheel bearing and spindle onto the hub which I found out is way easier this way.Yes,I rock,I know.... Cool Cool
All you need is a reduced PVC bushing,size 1-1/2"' under the hub.
You press onto the inner part of the bearing.Easy-breezy Razz

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Eurovan front rotors with adapter plates from T3technique.
5x112>5x114.3
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Assembling the Honda CR-V wheel 16"x6.5", and the bees knees:the hub cap fits Very Happy Now I can really piss off purists without having to give them the finger Twisted Evil
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Jaguar XJS calipers are not perfectly centered,but that will do for now,I don't have time to deal with that.They would need to be milled down a little bit
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Audi 200 Quattro 269x20 rear rotors
with adapters 5x112>5x114.3
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Yayyyy!! The hub cap fits here too Twisted Evil Twisted Evil Twisted Evil
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A view of the Porsche 930 style ,108mm stub axle (similar to Syncro 16")
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notice the difference in castings between these 2 rear wheel hubs
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installing a zerk fitting for greasing the bearings
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Cutting spring plates out of cutting board
I didn't have time to thermo modify them.Later.
Insyncro's trick of sliding a piece of hose on the end coil didn't work,not enough room on those SC springs Crying or Very sad

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So I lost 5 front wheel studs and I had to find a solution,quick!!
So I drilled the hubs @ 5/8" partially through,thus leaving a little shoulder for the new studs ,which are longer BTW.
I got them on my T3technique adapters,delivered with the wrong studs,Chris sent me the M12 studs later,thus those extra M14 press-in studs left over who saved my ass Surprised
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_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget


Last edited by ALIKA T3 on Mon Jan 14, 2013 9:04 pm; edited 2 times in total
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