Oregon Trail Syncro build

[panel]

[dkoesyncro]

The heat shield is thermo-cool insulation behind some tin that came from the exhaust tunel from a Passat found in a wrecking yard.

[dkoesyncro]

Some progress, more has been done than pictured! I forget about how consuming the little things are. I'm getting near completion but not before a handful or two of little things to do first!

[dkoesyncro]

A month later and a bit more progress, Maybe I'll be able to start it next weekend??

[4Gears4Tires]

Man, that looks fantastic.
_________________
'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[joetiger]

Wow! Incredible!
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Joe T.

'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'04 GTI 1.8T
'04 Golf R32

"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron

"Still, it's good to be afield."--VWagabond

Available Now! Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present

www.josephtrussell.com

[dkoesyncro]

4gears and Joe,

Thanks guys I am feeling very good about this iteration, It's been fun!

[dkoesyncro]

Things are getting near, I know I often am optimistic about this but I'm so close!

Here I've fabbed up what I believe will help cool the turbo, the D pillar intercooler exhausts itself into the singular lower plenum where the air will pass into/under the heat shield of the exhaust manifold.

The other pillar will house the trans cooler and the goofy bracket will hold the Volvo oil cooler

Launch control, just kidding! Seriously,this is for boost control!

I had to make new coolant pipes to work with this set up

Earlier I mentioned about lightning the load on the starter mostly for ease of working on this. I've opted for this lug/gang

Lastly, taillights! These are from "Super Bright LEDs"

Here's the air box, the Dodge/Chrysler V6. I have to figure out the rest of the intake plumbing. Possibly 2.5" rigid shop vac hose or similar??

[Vanagon Nut]

Great to see the progress and thanks for the images. Very interesting! Appreciated.

re: Dodge air box. I've used that box before. The reversible lid is nice and I'm sure you already figured this out but the Wix website shows the 1995 Dodge Caravan 2.5 3.0 and 3.3 with different size filters as 210 CFM. And, VW Mk3 is shown at 210 CFM, using same filter, for 2.0, TD and VR6. So, the smaller Dodge filter should handle air flow for a VW gas turbo or SC inline 4. And, the Dodge 2.5 and 3.3 use the same air box? Image links showing VW specs:


https://lh3.googleusercontent.com/20xxNg5DSn-hUZei...00-h799-no

https://lh3.googleusercontent.com/CQ1aOpL3nqUFPANm...00-h642-no

Dodge filter info image link:

https://lh3.googleusercontent.com/TN7aBYD3VR30Wmgq...68-h976-no

Neil.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

[dkoesyncro]

[Vanagon Nut]

[dkoesyncro]

A bit more progress and soon I'll be back in the seat.
The trans cooling/filtration has come together; thanks to the PNW guys Tom L, Tom M, Dale, David and the Garner Family of PioneerWagenWorks for helping me see this through!
From trans into Magnom filter

Magnom to Turbowerx pump (Weddle) and into the Canton "spin on" filter

In to the upper heat xchanger coupled with a thermostatic fan switch (swapping soon with a dial-adjust)

Makes its way now filtered cooled to the trans via the cross to the critical areas that the Toms and Paul Gaurd have taken the time to solve or extend the life of our gear boxes.

and two more, notice the black AN fittings

[dkoesyncro]

A bit more progress "the function element"
Wired up the puller fan on the modified TDI A/A intercooler that's the top blue switch. Next in the stack was the fan override for the trans cooler along with the Lil fella at the bottom to control the pump! This is all wired to the xline via the added fuse panel behind the glove box and relays next to the accessories behind the tail light.

The taillights are nice, they remind me of the Mk1 golf/rabbit although super bright! The gauge pod will be housing a trans temp gauge from intellitronicks and the dualing banjo intake temp from glowshift.

[dkoesyncro]

Today was the day of "judgment", I filled the gear box via the pump was that a slick "no mess fuss" what a joy. Hooked up the epas system and whoa, effortless you can practically steer it with mind control. After a shakedown and out of the garage it came, that 6:17 and these 27" tires what a goat! By brail ass 1st gear feels just an oomph higher than the 4:86 in gelande gear. I never got above 2nd gear in my neighborhood and an alignment is needed after doing the whole steering mod. Once again thank you to the folks of the PNW, that's Idaho, Washington and Oregon. I'm am so pleased and hope to move onto new things in this ever evolving syncro.

[Sodo]

Congrats !!
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[erste]

Nice!
So much ingenuity in this build. Amazing work, dude!!

[FrankenSubySyncro]

When can I come over and check it out in person? I will wear a mask with gloves and practice social distancing!
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Syncronize it!
1987 Franken Syncro (converted 2WD auto)
2004 2.5 SOHC Subaru
F & R lockers, decoupler, SS, 6.17 R&P
Trans Cooler
EMPI race prepped 930 CVs and axles
Bilstein coilover front, rear ProComp MX-6066R shocks, 14" hypercoil springs
30x9.5 15" BFG Muds
Custom skid plates
Nose job (custom front bumper) http://www.flickr.com/photos/subyvanagon/sets/72157624970330925/

[dkoesyncro]

Thank you all- it's been fun, challenging and rewarding. The alignment is scheduled for 4:00 today and until then I have luminated pressure switches to troubleshoot (reverse light/locker indicators)
Dave, I'll text you-
Eric, really liking your photography, you have got an eye!
Tom, thanks again for the arm chair theories and conclusive conversation, you've been great.

[dkoesyncro]

Reviving this thread as I'm about to embark into another phase of this machine. Although it works, but not without some issues I'm going to swap out my management for Microsquirt, the modified 1.8t harness just has some issues.... nothing consistent...often chasing gut intuition... without results or eureka!

While I'm swapping out the wiring I've thought about relocating the battery. Factory location is fine, I've just felt like these places might better serve camping and daily life. I've considered going to diesel layout but changed my mind and will stay at 15° and my engine bay is sorted out well enough. This leaves me thinking about under the back seat, any thoughts or opinions on location? (Just finished up reading a fair amount, I think I'll leave the battery alone and use the opposite for the house battery, aka westy style)

While addressing wiring, I will add a house battery and some convenience plugs,lights, USB's etc.

Cheers

[erste]

Looking forward to the updates!