Subaru 2.5l turbo conversion into a 91 syncro

fleet_maintenance · Posted: Sun Aug 03, 2014 10:16 pm Post subject:

I recently picked up dual horns (from an A4) at my friend's part out/everything $5 sale. Will be wiring them up soon, as my OEM horn sounds like (but is much quieter and raspier than) the laundry buzzer.

I'm pretty sure that most auto parts stores in my area will mix paint to match any factory color code, and fill rattle cans with it. Might be worth looking into if you are looking for the closest rattle-can match. IIRC there are intenet vendors that will do this too. They may not be able to ship via air/overnight/expidited though.I'm sure others with more knowledge will chime in.

Your van is looking better and better!

Syncromikey · Posted: Tue Aug 05, 2014 8:51 pm Post subject:

Thanks! I'm trying to get her all ready for her first long trip out to the coast. Once all is said and done I'm probably looking at around 4000 Kim's round trip so she needs to get all dolled up ... Wink

Well ... A bit more work today in the van. Started off by sanding the rough stuff down and putting some primer on it. Took fleet_maintenances advice and had gone to a local auto body supply store to pick up some colour matched paint ... Same colour as the original. While I was there I also picked up some other supplies like a couple cans of primer, some sand paper, tack cloth and a bit of cleaner. I did put have a type high expectations on this job other then trying to get it around the same colour rather then the silver and black chassis saver. But I turned out better then I thought ... It looks good from far ... Far from good. Laughing

When I was taping I could see that it had been painted before so it wasn't a surprise that the colours weren't a dead match but I kinda like the new colour more ... It's a bit redder. It's going to drive me crazy. I'm sure I'll be starting to look for body panels at some point soon ... I've already been thinking how I could step to up a paint booth in my garage once we are back home. I'm starting to wonder if owning and constantly trying to upgrade the van is a virus or worse! Shocked

A couple of before shots ...

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

A shot after a quick sand and some primer

A couple shots of the finished paint job. Maybe I'll just paint all the way around the lower half and call it two tone. Very Happy

I digress ... As I was waiting for the paint to dry I ended up cleaning up a bit in the front and putting everything back together. Also cleaned up and installed the new steering wheel. I really like the feel of it. Much thicker then the old stock one. It's like I'm driving a new van! Did a bit of BBQing too ... Such a nice summer day.

New steering wheel ...

Some BBQ lamb chops ... Mmmm ...

[Admin note: Non VW pictures are deleted from the gallery]

Have a good night!
Cheers,
Mike
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My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

luVWagn · Posted: Tue Aug 05, 2014 10:53 pm Post subject:

I do like the darker "Merlot" colour you have (now on top), as opposed to the titian red I have... Butt hey, two tone for now, paint booth soon Smile

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'91 Syncro 16 Reimo Hightop Conversion, eTDI

tschroeder0 · Posted: Wed Aug 06, 2014 7:36 am Post subject:

Can you say what year/model the steering wheel is from
Thanks

zeohsix · Posted: Wed Aug 06, 2014 8:18 am Post subject:

insyncro · Posted: Wed Aug 06, 2014 9:25 am Post subject:

tschroeder0 · Posted: Wed Aug 06, 2014 7:42 pm Post subject:

ouch, I guess that wont be on my list.
so the EV requires no spacers eh? hmmm.

luVWagn · Posted: Wed Aug 06, 2014 10:27 pm Post subject:

Syncromikey · Posted: Sat Aug 09, 2014 8:44 pm Post subject:

The wheel really is nice. I bought it a couple years ago and I can't remember exactly what I paid for it. I do remember it was quite pricey though but I'm glad I got it then cause I wouldn't be getting it now ... That's for sure.

So what's up with the tabs on the SA round headlights? I ordered a new set of headlight housings for the van thinking that the tabs would be the same but nope ... Not the same at all. Took a look at GW and they offer a conversion to the North American buckets but they are pretty pricey. I just couldn't justify buying a set of those, not to mention I wouldn't be able to wait till they got here cause we are heading out soon on holidays, so I started to make my own.

Here you can see the ones I have the tabs sticking out of the housing and mount directly to the body mount whereas the new ones have tabs sticking down only to orient them correctly when putting them into the cradle ... Maybe to provide spacing as well.

First off I headed down to the local bone yard to looks for a set of 7 inch round housings. Wasn't sure what vehicles would have them so I wasn't sure how long I would be looking around. Decided to start in the pickup section cause I do remember the older GMs used to sport them ... Maybe in the mid to late 70s? Only took about 5 minutes to spot one with a set in pretty good shape so I pulled them off ... Only another ten minutes more. Walking out I saw another pickup with a set of 7 inch rounds. Good to know there's a spare if I need it. Just over 7 bucks for the set with all of the mounting screws a couple of springs and the plastic clips to mount it to the body. Not sure I would need all of that but better safe then sorry so I brought them along as well.

The new housings don't quite fit. The addition of the driving light and maybe a bit deeper of a bulb housing will require a bit of cutting and finishing in order to get them to work out. The tabs orient perfect though so these should work out just fine otherwise.

A nice surprise was that the adjusting screw locations are in exactly the right locations too and even though the screws in the GM are much larger I should be able to get them to work. This may be easier then I thought.

I was thinking that I could just use a jig saw to cut the piece out of the GM part but I remembered after searching for about a half an hour that it had been submerged last year and was still out at my dad's place in the country so I ended up running to our local tool store and picked up some metal blades for the scroll saw. That worked out really well and I made the cuts.

Anyway ... That's it for now. More to come on this tomorrow.

Cheers,
Mike
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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

Syncromikey · Posted: Sun Aug 10, 2014 8:36 am Post subject:

After cutting it out and checking that the headlight housings actually fit into the new brackets I sanded them down, coated them with a rust inhibitive primer and painted them up. Currently they are sitting outside curing. They turned out pretty good. After the primer I just used some of the left over body paint to seal them up properly. Quite a long process painting like this. I really miss the powder coating rig. Will have to set that up again once I'm back in the house/garage. If I had powder coated it instead it would have looked much better and would have been done and cured in a bit over an hour ... Oh well ...

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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

Syncronoid · Posted: Sun Aug 10, 2014 9:38 am Post subject:

Syncromikey · Posted: Sun Aug 10, 2014 12:05 pm Post subject:

Syncromikey · Posted: Sun Aug 10, 2014 12:06 pm Post subject:

So I've drilled out the plastic adjusting screw mounts to the correct diameter for the new GM screws. I then carefully started the screw in the plastic mount making sure it was straight. Once I was comfortable that it was straight I took my impact driver and ran the screw in and out a few times so the thread was nicely cut and there was just the right resistance.

I then had to thin out the plastic retainer mount so it would fit into the new slot. Used the scroll saw for this again but I could have just as easily used a vice and a hacksaw.

Mounted it all up into the bracket ...

Put the headlight in ...

And ... It's rotated by about 45 degrees. Darn it! Rolling Eyes

Back to the garage to do a bit of tweaking.

Mike
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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

luVWagn · Posted: Sun Aug 10, 2014 12:49 pm Post subject:

Syncromikey · Posted: Sun Aug 10, 2014 4:57 pm Post subject:

I'm going to have to investigate that when we are on our upcoming holidays! Wink

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My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

Jake de Villiers · Posted: Sun Aug 10, 2014 6:36 pm Post subject:

Syncromikey · Posted: Sun Aug 10, 2014 8:11 pm Post subject:

Syncromikey · Posted: Sun Aug 10, 2014 8:12 pm Post subject:

Ok ... All done. Ended up just rotating the new mount in the old mount about 45 degrees. Drilled new holes, cut some slots for the tabs pulled the plastic clips out of the old holes and put them into the new ones. Everything lined up nicely after it was put together and the light housings were orientated correctly.
Now I've just gotta get the lights orientated correctly, pointing in the right direction.

Put the grill back on along with the front bumper ...

Over and out ...

Mike
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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954

Jake de Villiers · Posted: Mon Aug 11, 2014 9:40 am Post subject:

Looks good, Mike! Where did you get the 7" Cibies?
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'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
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Syncromikey · Posted: Mon Aug 11, 2014 11:58 am Post subject:

Got the Cibie lights from "aardvark international" ... "cibieusa" ... Pretty quick turn around considering it was shipped via USPS and had to go through customs.
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Love my Westy ...

My build: http://www.thesamba.com/vw/forum/viewtopic.php?t=528954


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Subaru 2.5l turbo conversion into a 91 syncro
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