Project Crunchie '87 Syncro Tin Top Overlander. (Pic Heavy)

[Signalocity]

So time to get the engine and transaxle out of the van, along with the gas tank. Everything came out pretty smoothly and just in time to catch a failing coolant pipe. A little bit of rust on the gas tank mount, but nothing that will require any fab work. The two routing/spacers for the fuel tank vent lines were busted up, which seems to be fairly common from other pics I have seen. I will address this later on. The mounting straps were not rusted through, but they were well on their way to being so.

[kbeefy]

wish I had the patience to do a complete teardown. I imagine you'll have a nicer rig than any VW ever sold when your done!
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86 syncro CHC, NorthWesty subbie 2.5, decoupler, locker, custom interior, 225/75r16 Duratrack's on CLK's, Toyo cabin heater, ARB fridge, 300w Zamp Solar, Gowesty bumpers/skid/rails, Fiama awning

'86 Syncro Westy. Stock for now.

2000 F350 7.3 CC LB 11' Northland Cabover

2006 Subbie OBXT

2002 Tacoma DoubleCab 4x4

1969 Mustang Basket Case 351c/FMX/9

http://kbeefy.blogspot.com/

[Signalocity]

[Signalocity]

The engine bay seemed to be to be more of an extension of the underbody to me, so I decided to keep it in the same color scheme. Another reason for staying with the lighter color on the underside is for visibility. Field repairs are so much easier when you can clearly see what it is you are working on, more so in poor light conditions. Even in a well-lit shop and on a lift, the dingy underside can be rather gloomy. All body and wiring grommets are being removed and threaded inserts are either being plugged or chased. I drilled out a 2 inch hole under the electronic junction box to afford me some better routing options for the wiring later on.

[danfromsyr]

there is NOTHING crunchie about this van, it's nearly as clean as yoru shop floor..
I might not eat off of either of them, but either would be a fine place for a little nookie.
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[Signalocity]

[Signalocity]

I moved on to detailing the transaxle for a bit, in an effort to break up the monotony of scrubbing the underside of the van. A wire brush on the drill came in handy for removing a lot of the oxidization. But once again, mostly time and elbow grease. I removed the flanges, shift linkage and swapped out the hardware in preparation for refinishing. I also did this to get access to all of the case. The transaxle is going out for a rebuild, but I decided to paint it prior to sending it out. I got more than a few weird looks for this, but it is the only way to get it truly detailed (short of getting the empty housings back from the builder, which was not an option). Once I get it back from the rebuild, I will touch it up. I prefer paint, due to the porous nature of the material. All of the hardware, brackets and such I media blasted and took to my local metal refinishing place for zinc plating.

[joetiger]

Wow, nice work! If I ever got anything on my Vanagon that clean, I'd be afraid to get it dirty!
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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

[Steve Arndt]

Impressive attention to the details. I can only imagine how many hours you have in this project so far.

Steve

[Signalocity]

[Steve Arndt]

I bet you had some sore shoulder after cleaning up the underside of the van working upside down.

[Signalocity]

[Phishman068]

Well I spent the whole day cleaning and wire brushing my transaxle for coating as well.....
And I was so excited to post my progress.....

But WOW. Yours looks SOOOOOOOO much better.
I hang my head in defeat. : /
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http://www.thesamba.com/vw/forum/viewtopic.php?t=559766&highlight=winter+rust
http://www.thesamba.com/vw/forum/viewtopic.php?t=482402&highlight=sunroof+syncro
http://www.thesamba.com/vw/forum/viewtopic.php?t=569774
http://www.thesamba.com/vw/forum/viewtopic.php?p=6864936#6864936

"Along with the ability to go fast, one looses the desire to hurry."

[Farfrumwork]

Holy crap. Nice work man! That is gorgeous.
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sold -> '85 Wolfsburg Syncro / 'Built' DOHC EJ25 (a great machine!)
'07 Legacy spec.B, road tuned stgII
'17 4x4 Sprinter, stone grey, SMB pop-top, on 33"s

"Blood stains, speed kills - Fast cars, cheap thrills - Rich girls, fine wine - I've lost my sense, I've lost control, I've lost my mind"

[Signalocity]

[Signalocity]

Generally I would not consider an engine swap and would make do with whatever a vehicle comes with stock, but the nature of this build had me thinking differently. I am also not a fan of aging 80’s fuel injection. I did a ton of research on the many different options available and weighed all the pros and cons of what I was trying to achieve. I won’t bother going into too much information on that, as it has been hashed out over and over again here in the forums. So sticking with the simple/reliable/detail theme, I opted for the Bostig conversion. Doing what I do, I can really appreciate the level of product, design and engineering they have put into their offerings. I located a factory long block, which was perfect for my needs. I wanted to trim out the engine to keep with the driveline theme. I also removed the front engine mount studs as they are no longer utilized and plugged holes with a couple of bolts for a cleaner look.

[Volkska]

Beautiful my man! Keep it up! I'm loving this thing
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2011 VW GTi 6MT (The Daily)
2003 Golf 2.Sl0w (The Flaming Turd)
1997 VR6 motor awaiting some love and a Vanagon
1986 Honda Elitee 150 awaiting a title

[insyncro]

I absolutely love seeing this attention to detail and that you chose Bostig.
Awesome
Bostig Syncros drive really well

[Signalocity]

[Signalocity]

Getting back under the van, I began cleaning out the fuel tank area. I had a broken bolt in one of the cage nuts from the gas tank strap that needed to be dealt with as well. I managed to get it drilled out, only to break off my reversing bit inside of it lol. I was able to get my air hammer on it and just busted it out of there (loudest thing ever). I will fit a nutsert to it later on. I have pulled all of the wiring up to the front diff area for the time being. The rust on the gas tank mount was minor and I was able to ziz it off with a flap disk and wire wheel. I threw in some better welds on the upper spring perches for fun, since they are more or less just tacked into place. The last picture illustrates the before/during/after process pretty well.