KEP Crossmember and Exhaust Interference

[Ar_sims]

Good morning vanagon crew.

I'm in the middle of swapping my 86 syncro to a 2.5l subaru and running into issues.

A little background on my project. I was browsing facebook marketplace like any good sadist that has an interest in old vehicles and came across a nasty rusty 1981(?) aircooled full camper. I was orginally looking to parts to convert my tintop to a full camper and this fit the bill. Looking through the photos I spotted a scangauge mounted to the column. Quickly I was able to get ahold of the owner and and he confirmed that it had a blown up 2.2l swapped into it. 3 hours of driving and $1000 later I was pulling it home to tear down.

Fast foward to now I aquired all my missing parts and started to get to work. I now have the engine and trans mated together using the KEP adapter and flywheel. I mounted the new KEP exhaust and engine and went to mount the motor in the van. I found with the transmission bolted to the body the engine carrier was about 2-3 inches to far back and would not line up with the frame rails. I removed the exhaust and motor mounts and tempoarly mounted the engine carrier in the correct location. Doing this it causes the mounting ears to line up with the adaptor plate which is inches away from where the engine mounts are located. To further complicate the matter, the new KEP exhaust hits exactly where the engine carrier crosses between the frame rails.


My question is are all KEP engine carriers the same or has there been an updated design rolled out? I have browsed countless photos and can't find a solve as my set up is not working.


Worse case scenerio I will order a van cafe carrier and since the KEP one was essentially free but if I can save the $400 I will.

[Phishman068]

I had the exact same problem.
Bought a used conversion that was KEP but old, found the bar didn't fit properly in my syncro- bought a replacement bar from them- and it interfered with their exhaust.
Ended up having to buy a new one of those too.

In the end, I learned not to buy used mix and match Subaru parts- you end up spending 150% of what you thought instead of saving.
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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."

[Ar_sims]

Well at least I know I'm not crazy now. Luickly I have very little into the swap and have sourced everything else from vc/rmw. If I was starting from scratch I would certainly buy a complete kit to ensure everything is compatiable.

[MarkWard]

Are we talking about 2 vans? The air cooled vanagons had a shorter transmission. About an inch and a half. That would account for the differences. Also, a syncro has the engine mounted lower than stock 2 wd vanagons.

So, not quite understanding your post, there are subtle reasons things aren’t matching. Probably the only reusable part would be the adapter, flywheel and clutch. Sorry if I misunderstood your question.

[Ar_sims]

Correct the donor was an air cooled van. On KEPs website they only list one carrier which is the reason I was questioning the fitment. I'm now researching which carriers would be compatiable with the KEP exhaust and adaptor plate.

[Phishman068]

I can tell you that the RMW oil pan and heat shield work with the kep stuff. I had to modify the muffler hanger from KEP a bit and the heat shield from RMW a bit- but I’ve been running that combo for a few years now.
_________________
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."

[GoEverywhere]

I didn't use the KEP carrier, but when I converted my aircooled chassis I had to use a conversion transmission mount and extend my shift rod because the AC tranmission is about 2 inches shorter than the water cooled trans. Maybe look at the aircooled's transmission and see if its got a different mount on it?

[MarkWard]

Unfortunately the syncro trans mounting is completely different from all 2wd. I have no experience swapping Subaru engines, but it’s unlikely a 2wd conversion kit from any year vanagon would work as a direct fit for a syncro. Syncros are very unique.

I’m sure the adapter is fine, but as suggested, you should probably shop syncro specific parts to get it finished up, if you can’t fabricate yourself out of this jam.

You might be able to sell the parts you can’t use. More 2wd out there. That KEP only advertises one kit for all is not surprising.

[markswagen]

kennedy make 3 different support bars, early aircooled, regular wbx and syncro.
if you look at the parts you have to will see that the intake boot, from the airbox to the throttle body, its squashed, for the wbx they are not.
you'll need a syncro support bar, and a different intake boot.
this is from the first aircooled to subaru conversion l did, not the intake boot.

later intake boot.

l don't have pictures to show the difference in the 3 different support bars.
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markswagen {mobile mechanic} san diego area all early VW's cared for.

619 201 0310