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My syncro westy: 3 months so far with LOTS of pics.
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hrtm
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PostPosted: Fri Apr 01, 2016 8:16 pm    Post subject: Reply with quote

hans j wrote:


Am I the only one who feels like this?
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HA! I feel like this 100% and all I've done is try to un-MacGuyver untold previous owner screw-ups & keep my relatively stock '84 Westy on the road, let alone do any modifications to it!
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Steve Arndt
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PostPosted: Sat Mar 12, 2016 10:42 am    Post subject: Re: My syncro westy: 3 months so far with LOTS of pics. Reply with quote

Nice build thread. I learned some useful tricks. On to my Passat front brake swap.
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PostPosted: Wed Dec 31, 2014 8:02 pm    Post subject: Reply with quote

hans j wrote:

Link

Hans, just reading your build-thread linked through your sig for the first time. Love it so far!
Is the music in the above video from Ani DiFranco? If not, who is it? Love it!

Wishing you a Happy New Year, and hope to eventually meet you when visiting family in SLC!

Cheers,
Brian.
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Syncro Jael
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PostPosted: Wed Nov 12, 2014 10:32 am    Post subject: Reply with quote

Great work Hans! I just ran a crossed this thread. We need to get a group and get out more, if we can just get the time off work? Rolling Eyes

I too am looking to get a cold air intake mounted up on mine. Yours turned out very nice.
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hans j
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PostPosted: Sat Mar 22, 2014 9:44 pm    Post subject: Reply with quote

Ok I got a couple new neat things built and working on more!

First off I finally got my front CV boot protectors built. Alistar, you totally won... It only took me a year to finish them! Initial thought is they are going to get in the way of what I was thinking of doing for my swaybar disconnects, soooo that design might change. Other than that, I'm into them about $20 in stainless steel (with lots left over!) and I used an old rubber floor mat from a Mk3 golf as the rubber. I think I'm going to change that out for something else, someday.

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Next up I finally got my artificial rain gutters made! I met a guy who works at a metal fab shop while working on another project (https://www.kickstarter.com/projects/1884724272/pianobike/posts. Anyway, he has a 90 ton metal brake in the shop and all sorts of other awesome tools I don't have. So a couple of hours, $30 for 11 gauge stainless steel and a $30 bottle of whiskey turned into these:
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The stainless mounting hardware cost as much as it did to make them Rolling Eyes
But when you mount all 6, it's awesome and will hold anything (2 kayaks) without flexing the top. Plus I've only seen the European vans with these, so I feel a little special. I also wanted to integrate a shovel holder into it, and it seems to be working pretty good too!

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With roof rack and shovel attached:
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I have another slot for a hoe or another shovel in the rack, I still need to get stuck to see if I want to tote one around...

Now I'm really excited about this next one. Ever since I have gotten into the $yncro world, I've loved the look and functionality of a cyclone pre-filter snorkel. I used a Donaldson Top Spin #H00243. It flows 200 CFM and has a 3" outlet. Note: Be sure to calculate your engine CFM to make sure it will work for you. I'm right on the edge with this one, but the next size up is a bit larger, and I like this size. Then I used about 9 pieces of 3" of random steel tube I found around the shop and TIG welded them all together (I have since added 1.5" on the top to raise it away from the rain gutter, I didn't want water to get sucked up into it). The 3" made it nice to fit on to my existing snorkel tube to the air filter I already built, but 3" does NOT fit nicely behind the grill... Lots of modifications ensued...
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This photo has the extra 1.5" added.
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Other minor things are I installed these neat little guys:
http://www.sierraexpeditions.com/index.php?l=product_detail&p=200. I also got the Blue Sea dual USB outlet for the dashboard from them too. Just a little cheaper than the price on Amazon Smile
I got my inverter at least mounted in place, but not wired yet. I'll post pics when done with that one.
I've also been tidying up other stuff in the van, getting ready for summer trips. It's nice to have most of the big stuff done.

Upcoming projects:
Dual rate, remote reservoir coilovers for the front Cool I'll find out in the next couple of weeks if it works! Lots of time in research for this one. Springs are ordered and parts are being machined. But learning about suspension geometry, it's amazing how well the syncro was set up from the factory! Full weight, mine is only about 100 pounds different front to rear and the cross weight is almost perfect. My total weight, fully loaded and full of fuel is 5250 pounds, just over the GVWR of 2340 KG (5158 pounds) in the door jamb. That's with a TDI, diesel fuel and dual spares on the back! Roadhaus lists 5512 pounds for the syncro westy? I'll post up photos and most of the specs when it's done.
I'm also shortening the valve cover and other things in the engine compartment finally. I'm over sleeping on the tall box and want to do something similar to what Stephans AutoHaus does with the 1.8T engine lid. I'm pretty sure I can make it all fit under there, and it will add back insulation too. This is my long term project to get done.

That's all I can think of right now. I've been checking things off my list pretty regularly and it's pretty much ready to go anywhere in the world at a moments notice! Now to just find more time off...
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hans j
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PostPosted: Mon Feb 03, 2014 8:35 am    Post subject: Reply with quote

I had 1.18 3rd and 0.73 4th installed since the TDI doesn't like higher RPM. When I had stock gearing I could pull Parleys in 4th gear at about 60mph, but with the taller gearing I can't without my EGT's getting too high.

According to a speed calculator, yours looks is really close to a stock 4th gear. http://www.scirocco.org/gears/ and syncro gear chart here http://www.club80-90syncro.co.uk/Syncro_website/Te...os%205.htm

I drove around for quite some time on stock gearing with the TDI and it was just too short for comfortable freeway driving. Now I can drive it at nearly 75mph with the same rpm as I was driving 63mph or so.

If I had a gas engine, I don't think I would change ratios at all unless I went with giant tires (then change r+p).
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Syncro Jael
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PostPosted: Mon Feb 03, 2014 7:53 am    Post subject: Reply with quote

hans j wrote:
trans has been great! There was a little more debris than I would have liked to have seen during my first oil change for being a brand new unit, but there was also machining involved inside. The pump and filter is high on my list of items to buy, especially before the heat of summer.

I am running the stock 4.86 r+p with 215/75-15 tires. I wish we had an even lower, low range for crawling without sacrificing top speed. Oh well, it still does everything I ask of it Smile


While mine is on the build bench this week is there anything that you would suggest I have done?

I am also 4.86 with 215/75/15 tires. My previous trans build papers states that a taller 3rd and 4th were installed. But I am a little high geared for the Utah canyon passes and want to go back to stock gears. Is that what you run?

I am at 58mph in 4th gear at 3000 RPM GPS checked. Is that a stock 4th?
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hans j
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PostPosted: Sun Feb 02, 2014 11:06 pm    Post subject: Reply with quote

trans has been great! There was a little more debris than I would have liked to have seen during my first oil change for being a brand new unit, but there was also machining involved inside. The pump and filter is high on my list of items to buy, especially before the heat of summer.

I am running the stock 4.86 r+p with 215/75-15 tires. I wish we had an even lower, low range for crawling without sacrificing top speed. Oh well, it still does everything I ask of it Smile
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ShootingFish
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PostPosted: Sun Feb 02, 2014 10:12 pm    Post subject: Reply with quote

What R&P are you running?
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Syncro Jael
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PostPosted: Sun Feb 02, 2014 9:25 am    Post subject: Reply with quote

How is the AA tranny doing since you got it installed?

Matt should be building mine this week and hopefully I get in installed by Valentines weekend. I paid for the aluminum gear carrier and aluminum main housing along with the inside oil plates, new main shaft, and other goodies to prolong it's life.

That will be my wifes "roses and chocolates" in that shipping box! Don't tell her though. Shocked

Unreal the mileage you are getting with the diesel. Laughing
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hans j
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PostPosted: Sat Feb 01, 2014 7:02 pm    Post subject: Reply with quote

Wow. I have so much to add to this thread and so little time.

Cliff Notes are as follows: Trans is awesome. I got 27.5 mpg on a 2300 mile trip to Oregon and California. Cruise control is awesome. These parts came in the mail and will be installed soon: Donaldson Top Spin, 800w inverter, 80/100 light bulbs, and probably a whole bunch of other stuff...

I'm building some of the fancy European roof rack artificial rain gutters that go further down and rest in the steel rain gutter. Girlfriend bought a touring kayak so we will be doing water oriented trips now too Smile

Winter is half over which means it's getting warmer. I still don't have a cabin heater but found out if you tuck a blanket in the top bunk and drape it down over the bottom bed it keeps it warmer while sleeping!

I'm trying to figure out how I can get the time off to send my syncro to Europe for the Syncro 30 event in Graz Austria Very Happy

And I've updated my blog a little bit but still have a couple trips to add. http://hansallover.wordpress.com/
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hans j
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PostPosted: Thu Nov 14, 2013 1:53 pm    Post subject: Reply with quote

Forgot to add a couple pics so these are out of chronological order...

rear spring setup mocked up
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I think I could have moved the lower perch back slightly but not too much. I need to get a gopro under there and drive around to watch and see if pivots are even needed.

Trasharoo!
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I always end up picking up someone elses trash while camping and it always went inside (where the extension cable was). Now I can keep it outside! Will be nice to haul firewood in too.

kryptkat wrote:
Looking good Hans. You're Da Man!! Looking forward to doing some good riding with you again. Wife and I are planning to attend Buses by the Bridge in January, ya coming?


Definitely soon! Not sure I'll be able to make BBB, taking a week off work to make syncrofest and syncro solstice! My other time off will likely be spent in Germany Cool
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PostPosted: Wed Nov 13, 2013 4:50 pm    Post subject: Reply with quote

Awesome.
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PostPosted: Wed Nov 13, 2013 1:50 pm    Post subject: Reply with quote

Looking good Hans. You're Da Man!! Looking forward to doing some good riding with you again. Wife and I are planning to attend Buses by the Bridge in January, ya coming?
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PostPosted: Wed Nov 13, 2013 10:20 am    Post subject: Reply with quote

tam_shops wrote:
Wow, nice work, on everything!


Too cool w/ the sticker and new dash lights! What kind of paper/product did you use to print that sticker? What is weeding a sticker? Cutting? If you cut that w/ a knife, Wow x10! LOL My head light decal (or is it paint?) is worn off and I'd been thinking about using some oil paint to fill in the lines again, but was worried I'd just make a mess of it...

Wonder why the Canadian Vanagons don't have an O2 sensor?


Thanks Tam, and keep up the work you have been doing too! I don't know why they didn't have an O2 sensor light (you should still have an O2 sensor, at least mine did). Probably federally regulated like the extension cord pull out for shore power.

I used a sticker die cutter to make my glow plug sticker. the stock ones are actually see through and that's the down side to my setup, I might do it right later... Check out this thread for a little more info: http://www.thesamba.com/vw/forum/viewtopic.php?t=573133&highlight=dash+wiring

sanchius wrote:
Great and inspiring thread! Plus, we had a very cool canyon wall house at 4th ave & City Creek Canyon back in the 80's, so your pics bring back lots of memories.

Since you seem to have a lot of fabrication ability mixed with a fair amount of that OG Original Germanic "it's got to be exactly right" spirit, you might get some inspiration (or decide it's simply easier to buy it) from the beautiful syncro & vanagon bits at:

http://www.syncro-werkstatt.de/MRB-Fahzeugtechnik.htm

Kanister aus VA by MRB für 12Liter Benzin, Diesel oder Wasser abschließbar, leicht zu tragen, passend in 14", 15" und 16"
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Thanks, City Creek is pretty popular now with the new mall that was built! I just found out about HRB a couple months ago and love their stuff! I have been thinking about a spare fuel can like that too, that's just one of the reasons I mounted my tires inside out. I'm likely going to Germany next year and have plans to visit as many vendors as possible!

I'm also highly considering taking the van on a boat ride over there for Syncro30, at least most of the big money has already been spent on the car!! Now to save for trips Very Happy
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PostPosted: Wed Nov 13, 2013 5:51 am    Post subject: Reply with quote

Great and inspiring thread! Plus, we had a very cool canyon wall house at 4th ave & City Creek Canyon back in the 80's, so your pics bring back lots of memories.

Since you seem to have a lot of fabrication ability mixed with a fair amount of that OG Original Germanic "it's got to be exactly right" spirit, you might get some inspiration (or decide it's simply easier to buy it) from the beautiful syncro & vanagon bits at:

http://www.syncro-werkstatt.de/MRB-Fahzeugtechnik.htm


Halterwinkel 251 611 823C für den Bremsschlauch am syncro vorne in Edelstahl
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Halter für Unterdruckdose für Sperrenbetätigung (Diff Lock Actuator Bracket T3 front and rear)
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Kanister aus VA by MRB für 12Liter Benzin, Diesel oder Wasser abschließbar, leicht zu tragen, passend in 14", 15" und 16"
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PostPosted: Tue Nov 12, 2013 11:37 pm    Post subject: Reply with quote

Wow, nice work, on everything!


Too cool w/ the sticker and new dash lights! What kind of paper/product did you use to print that sticker? What is weeding a sticker? Cutting? If you cut that w/ a knife, Wow x10! LOL My head light decal (or is it paint?) is worn off and I'd been thinking about using some oil paint to fill in the lines again, but was worried I'd just make a mess of it...

And, thanks for explaining to me why I had 2 bulbs w/ no purpose on my dash. I've been wondering for months now! Things w/ no purpose and holes for no reason drive me crazy in that special kind of way! Wonder why the Canadian Vanagons don't have an O2 sensor?

tam
hans j wrote:

And so my car, being Canadian, didn't have the O2 sensor bulb? Oh well. All the tracks are there, so I just poked a needle through and put in a new 12v LED (with the polarity correct!). See small circle near bottom!
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The circle on the right is to complete the circuit for the track. I guess I could have put any voltage bulb I wanted there and then installed the correct resistor for it... But I didn't feel like it. Plus Radioshack had 12v ones, but only in red. So my glow plug light is red instead of orange. I'm already over it since it's done. I did dribble a little bit of solder into the LED connection, it was a little sporadic in working until then.

Annnndddd I didn't have a diesel cluster to steal the center display out of... So I had to improvise, again.
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And what I got was an awesome, VERY small glow light symbol!
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Oh how cute...
It's a little more white and thicker than the other symbols, but it SUCKS weeding stickers that small.
Looks good though!
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I can make you some if you really, REALLY want one.

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PostPosted: Tue Nov 12, 2013 10:56 pm    Post subject: Reply with quote

Huh... Guess I need to update this more frequently so I don't spend three hours telling you all what's new... So here's what's new!

During Syncro Solstice, I realized I wanted different suspension. I looked into all the options, costs and benefits and decided to keep it with my theme of build it myself. Also some talk of swaybar disconnects came up (search the archives) and that's on my list. But I needed some information.

First thing, check articulation:
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Close up of sway bar disconnected:
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Results were actually sort of good! It's slightly better than a stock XJ Jeep! And one inch was gained by disconnecting the sway bar. I also took all sorts of shock measurements which are written on a small piece of paper and probably lost by now. Note to self, take photos of stuff you write down. Anyway, turns out the front can lift about 17 inches off the ground with the sway bar connected. Once I get my hands on a lathe I will be making rattle proof disconnects Wink

Next up was to corner weigh:
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Results were as expected, it's a heavy pig, but reasonably balanced! Weighed with me in it, 1/3 tank of diesel, lots of extra weight added to simulate full load. I also weighed all the individual pieces of suspension to calculate unsprung weight. Seems I don't have photos but pretty much each corner weighs in around 120 pounds and the rear weight is halved (when talking unsprung weight) due to it being a semi-trailing arm design. All of this will come in handy later...

Quick off road time waster before hockey to check out some dirt roads and measure shock temperatures
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Dual spare tires!
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Pretty much mirrored what works on the other side. I was thinking about making brackets to bolt on that would be different so I could add a ski rack or something, but now I will be cutting apart a bent steel wheel and just welding a bike or ski rack to that and bolt it on to the tire rack!

Then I went and hung out with the local 4x4 guys... That was interesting...
(text and photos taken directly from here in case you missed it Wink : http://www.thesamba.com/vw/forum/viewtopic.php?p=6767250#6767250)

"Back to syncro abilities! I went out with one of the local 4x4 clubs to a training day and drove with them as well. The trail was Mineral Basin Road in American Fork canyon Utah. Google and youtube it for thousands of hits. You will specifically find Rock Garden hits and videos (where these photos were taken). Original thread here:
http://www.rme4x4.com/showthread.php?98665-2013-Summer-Quarterly-Training-Day-Trip-Report

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In short, the stock syncro is extremely capable. I'm only sitting at 18.5" height with 215/75-15 BFG deflated to 22psi. TDI gave plenty of power. I scraped more coming down the trail than going up, even an inch more of clearance would have been significant on this trail.

The syncro also requires a different kind of spotting than a regular 4x4, my spotter found this out very quickly when I was taking lines he never would have thought of and passing them easily. He noticed our ability to just drive straight over stuff and not try to place the wheels on top of rocks to get a solid axle to pass.

I did touch stuff quite a bit still. Basketball size rocks will do that for you... Items I will be beefing up after driving this road: Front control arms could use some armor, thinking 11 gauge plate welded to the bottom. Rear skid plate needs to be bent back down and possibly beefed up. My sliders worked great but I want stronger mounting points. Want to bolt a heavy skid plate to the front diff carrier, I skid along that a few times but height will also help. I barely touched the driveline protectors, but they are getting upgraded anyway when I build my CV joint driveline. Both rear mudflaps came off, never had an issue with them, but this trail was particularly rocky so I'll have to be careful next time I go out.

I'll think about doing this trail again when I build my suspension, should be night and day with what I am going to put in."


And then it was time for a vanagon trip!
Mini-dirt-tour-Utah
We had been talking about a big dirt tour of Utah but time never panned out for all of us so a quick over nighter was in order. These are just a few of the photos taken, but the best images are in my memory. Thanks Jeremy, Pam, Bob, Craig and Paige. Super fun trip, let's do it twice a month.
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About 100 miles of dirt road and camping at 10,000 feet with an amazing sunset. Found out my diesel REALLY likes the speeds of dirt roads, every time I checked the scangauge it was reading 40mpg average! Seriously love it.

And this showed up,
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And then these parts,
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make these parts,
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out with the old
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in with the new!
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Installed!
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tire clearance with 215/75-15 on ET44 Eurovan wheels with 15mm spacers. Ground down and TIG welded joints. Should be plenty of room for chains!
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So about my suspension. I had been looking for quite a while and finally settled on building this. Hindsight would just have me buy the adjustable FOX shocks and zero-lift springs but I HAD to do something different I guess. Plus this will be about $700 cheaper than that option. It's just taking longer to build than I wanted, but that's what you get with small companies.
For now they have 400 rate springs installed since I haven't gotten the rest of the parts for the front machined (external reservoir coilovers also). I'll likely do 600 rate in all but left rear, that will be 650. They will all have coilover style adjustments for adjusting height and corner balancing the suspension. I do it because I can Very Happy

Now if you go back and look closely you will see the transmission missing...
It's like a little coffin:
Image may have been reduced in size. Click image to view fullscreen.

Yup, 3/4 slider broke Sad Two days before SoCal MogFest and a week before a planned camping trip to Zions. While my S4 is fun to drive, it's not that great of a camper! I had to set up my tent!

But it worked out, my brand new trans just got done getting everything done but the decoupler (I spend a LOT of money and time on my hobby but that one has to wait for now). And I settled on the 1.14 3rd and .73 4th for my driving style. Thanks again Jon for all your advice, even though I did something different. Plus while the van has been sitting there, I was able to install the rear suspension. Those old spring perches weren't even mine, they were core arms. Mine were much worse! I'm amazed they held together! I knew they were going bad, I though about it every time I drove it. Pretty sure the new ones aren't going to break.

I was also able to fix a factory cruise control stalk and get that installed. A few minutes sorting wires and looking at my wiring diagram and I have cruise control! Really can't wait to use this feature Cool
That's about it for tonight, I'll add more when I get my trans and can drive it again!
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1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181
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cookrw
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PostPosted: Thu Aug 15, 2013 7:10 pm    Post subject: Reply with quote

This is awesome. I wish I had as much get up and go as you!
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'71 Super 'Vert
'84 Vanagon GL (w/ Sunroof!)
'96 Jeep Cherokee
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hans j
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PostPosted: Fri Jun 28, 2013 7:39 am    Post subject: Reply with quote

TheBlueTurtle wrote:
What are you wheel/ tire sizes ? Are those stock 14" steelies?


Stock early Eurovan wheels. 15x6 ET44 plus 15mm spacers on each corner makes them ET29 (plus longer studs). 55 pounds each with BFG AT 215/75-15.
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