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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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 Posted: Thu Apr 18, 2013 4:26 pm Post subject: The Alijonny Syncro revival story |
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So, I decided to get myself neck deep into a project of awesomeness. Jrobewesty posted up this Vanagon with what is thought to be a grafted westy pop top and 1995 Jetta ABA 2.0L conversion. I had the idea in my head to find a fixer-upper westy, but not necessarily a Syncro. One VW on my long bucket list was a Syncro, and I now own one! WHOO!  I picked it up and also picked up a grey Westfalia interior from a guy named Sig who has a VW repair shop near Wisconsin Dells. I am currently working on this at my repair shop in Hammond, IN when I have spare time. Stop by if you're in the area.
Anyway, I already have some parts ordered and a ton of ideas in my head about what I want to do with it, and I hope to keep updating this post with my progress. The plan at this point is to have a camp-able vehicle by the time Busses by the beach rolls around.
To start with, I have some photos of the seam rust I will be tackling:
I guess it can be called seam rot, not seam rust, eh?  but, the van seems solid everywhere else, so I feel strongly that I can save it and make it an awesome camping/adventuremobile! I will post more photos as I go, I just need to get them loaded up and posted here. Thanks for looking!
Last edited by alijonny on Mon Apr 22, 2013 10:45 am; edited 4 times in total |
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dobryan
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Joined: March 24, 2006
Posts: 16494
Location: Brookeville, MD
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Fri Apr 19, 2013 10:30 pm Post subject: |
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Time for an update...
So I finally got around to doing some things, and my wife came to the shop to chip in
She is enthusiastic about getting this camper going which I love, but I feel like she is doing more work than me hahah.
My wife, EDA wasn't too interested in keeping the carpet, so that was the first to go.
Then we assessed the floor and it's crusty, but solid appearance:
Then, I put my wife to work. Hahaha, she scraped, scrubbed, and then prepped the floor for some grey por 15:
She is a natural!
I decided to tackle the trim around the cooler door, and see if the cooler functioned. I bought the camper stuff with unknown history, so I plugged it in to the extension cord while the wife was slaving away:
After heating the trim and stretching it back Into its groove, I got my trusty fluke 87 out and used the temp probe. After about an hour we were down and cool 
26.3*F sweet, at least the thing will get us by for the time being...I really would like to upgrade to the newer style fridge...eventually.
Anyway, I did some poking around on the lift to see what was what and was pleasantly surprised by how solid the undercarriage is. A little surface rust, and I have definitely seen worse in newer cars.
I think it's time for me to invest in a good sandblasting cabinet, powder coating equipment, and a used kitchen oven.... or a ton of elbow grease!
And the final thing I wasn't expecting was the install of an auxiliary battery!
Although the aux one has a date code of 1999, it is in place, I just need to figure out how they are wired up. Sweet!
Anyway, that's all for now.  |
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luVWagn
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Joined: February 21, 2008
Posts: 1340
Location: Snoqualmie (WA)
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| Posted: Fri Apr 19, 2013 10:53 pm Post subject: |
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Good stuff! And I see that your wife changed footwear along the way 
My wife isn't quite so handy, but she does like to vacuum and clean the van, at least.
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'91 Syncro 16 Reimo Hightop Conversion, eTDI |
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JeffRobenolt
Samba Member
Joined: February 25, 2007
Posts: 1513
Location: Wisconsin
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| Posted: Sat Apr 20, 2013 5:15 am Post subject: |
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I liked that carpet!!!
I'll check on some carpet for ya when I get home tomorrow.
Looks like your jumping right in, the only way to go!!
I never looked to see if it had an auxiliary battery. I'm surprised it has one.
The jumpseat anchors in the floor look factory.
I would think if it was a base model it wouldn't have those. That van is still a little bit of a mystery with the poptop and other options.
I have been eyeing up a powder coating kit from Eastwood, my buddy picked one up and has awesome results with it.
Take care, Jeff
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| jfats808 wrote: |
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CdnVWJunkie 
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Joined: February 01, 2004
Posts: 1110
Location: Sarnia, Ontario, Canada
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| Posted: Sat Apr 20, 2013 5:39 am Post subject: |
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I really think that van was a very good buy. $4K for a running driving Syncro weekender westy has to be one of the best deals on here for a Syncro in a long time. I think it's great you're going to resurrect it. The fact it has a I-4 in it already is another good bonus.
I'd consider contacting VW and getting a birth certificate to see how it came configured. I've got a number of them over the years. It's a neat feature that VW offers. Gives you the build date and build data for the vehicle.
Good luck with the project. |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Sat Apr 20, 2013 6:46 am Post subject: |
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The Jumpseat mounting points for sure look factory. I will keep them around since it could be beneficial to have a spare jump seat just in case.
Jeff, I can save the carpet for you if you would like lol. I would like to put something less *exciting* on the floor.
I will eventually get the birth certificate for it, but feel I might be let down in knowing that it was a stripped-down base model Syncro. Either way, I figure it's a great starting point and a clean slate to make it into what we like. There is a lot of sorting, cleaning, and other various work that needs to go into it, but it should prove to be a worthy candidate. |
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D Clymer
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Joined: December 22, 2005
Posts: 2978
Location: Issaquah, WA
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| Posted: Sat Apr 20, 2013 8:28 am Post subject: |
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The 1990-1991 base models did have factory installed jumpseats. They were basically a Carat inside, but with no side table, no carpet, and tweed seats. That van fits the description of a base model Syncro to a T except for the mystery poptop, which I agree looks very well installed.
Anyway, glad to see the progress on putting this one back on the road.
David |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Mon Apr 22, 2013 9:44 am Post subject: |
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I am getting ready to order a fresh canvas and seal kit and see that the top is the later screw-in style, which is great. Will there be any kind of identification on the pop top itself? Like a serial number or something?
I am tempted to pull down some portions of the headliner to get an idea of how well the poptop is attached, but I don't want to ruin anything yet... |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Wed Apr 24, 2013 10:18 am Post subject: |
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Update for 4/24/13:
I got some rust repair panels and started on the worst panel, behind the sliding door. I ordered the whole panel from CIP and it showed up! As I cut, it is all looking like an easy enough panel job, I am getting some good solid metal that I will recycle around the van as I go, I plan to use no bondo or filler, maybe lead if I am feeling crazy. Anyway, I have some time to decide. I pulled out my manual nibblers and started cutting. LOOK:
I see solid metal! Looks like I have something to build off of. First thing I will do is measure the inside to the outer panel and weld some new steel for the inner to outer structure.
Here is the panel, It is Klokkerholm, not exactly like factory, but I will make sure it is attached as structurally sound as possible, and it will be all welded.
That's it for now, need to strip down the interior and get it ready for some welding. |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Fri Apr 26, 2013 8:47 pm Post subject: |
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Update, I got the canvas from busdepot.com, it was a time consuming job. I had help from my employee, his brother, my wife, and another buddy, we got the top off and ready for the new cloth. I also did the seal kit which turned out nice.
Getting my wife used to using a torch for no real reason yet... Lol I just thought of a cool live action shot.
Two of the guys helping were short, so to aid in removal and prevent damage, I let the air out of the tires kinda looks like I'm parting it out, or am preparing myself for the looney bin
Top off with my wife cleaning the old weatherstrip adhesive gunk off the edge.
You know, it's funny. I had an idea of how I wanted to measure the top, and six others standing around had the idea to "screw it down and it will fall into place". Well, I humored them and ended up taking double the time to get everything lined up the way I wanted it.  what's the saying? The cheapest way usually ends up being the most expensive way? Lol yup.
We have an untorn tent! Yeah!
More carnage, just less parts van status
And finally, my beautiful wife. In a rush to get the camper together so she can sleep without the worry of bugs getting into the torn canvas. Hahaha!
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ALIKA T3
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Joined: July 30, 2009
Posts: 6345
Location: Honolulu,Hawaii and France
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JeffRobenolt
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Joined: February 25, 2007
Posts: 1513
Location: Wisconsin
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| Posted: Sat Apr 27, 2013 6:55 am Post subject: |
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WOW you have been busy.
Way to dive in, the only way to do it.
Jeff
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specialev
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Joined: March 25, 2011
Posts: 281
Location: Mukilteo WA
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| Posted: Sat Apr 27, 2013 7:08 am Post subject: |
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Still getting some use out of that crummy rug at least, I see.
Keep at it! |
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JeffRobenolt
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Joined: February 25, 2007
Posts: 1513
Location: Wisconsin
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| Posted: Sat Apr 27, 2013 7:43 am Post subject: |
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Why is everyone dissing the rug!!! 
Going to try and pull some carpet for ya today, I'll let you know how it goes.
Jeff
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| jfats808 wrote: |
| Most, some, few is not all. You can always learn something from everyone , even the fool. |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Wed Sep 11, 2013 9:45 am Post subject: |
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Well, since I am waiting on the insurance company to figure their stuff out, I saved enough to get the bumpers I want.
Me Gusta. Thanks, Van Cafe!
Last edited by alijonny on Wed Sep 11, 2013 9:52 am; edited 1 time in total |
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JeffRobenolt
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Joined: February 25, 2007
Posts: 1513
Location: Wisconsin
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| Posted: Wed Sep 11, 2013 9:51 am Post subject: |
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 Looks good!!!
The body looks like you put a little more time into it.
No news on the trans?
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| jfats808 wrote: |
| Most, some, few is not all. You can always learn something from everyone , even the fool. |
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alijonny
Samba Member
Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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| Posted: Wed Sep 11, 2013 9:52 am Post subject: |
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Well, since I am waiting on the insurance company to figure their stuff out, I saved enough to get the bumpers I want.
Me Gusta. Thanks, Van Cafe! |
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r39o
Samba Polizei
Joined: May 18, 2005
Posts: 9800
Location: San Diego
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| Posted: Wed Sep 11, 2013 10:11 am Post subject: |
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| alijonny wrote: |
| Well, since I am waiting on the insurance company to figure their stuff out |
What?
Little disconnect here. I don't see any post about that.
There is a story missing, I think.
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"Use the SEARCH, Luke" But first visit the Vanagon FAQ!
1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....
Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently) |
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alijonny
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Joined: November 01, 2007
Posts: 328
Location: Des Plaines, IL
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