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87 Westy Syncro TDI conversion and restoration~lots of pics
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Signalocity
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PostPosted: Thu Nov 19, 2015 11:25 am    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Coming together nicely, well done!
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87vanwes
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PostPosted: Fri Nov 20, 2015 1:59 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Signalocity wrote:
Coming together nicely, well done!


Thanks Signalocity, that means a lot coming from a guy like you.
Your work is spectacular and a tough bar to keep up with.
I always look forward to new posts from you on yours.

It's good to here from a fellow tar heal. Maybe we will cross paths one day.
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87vanwes
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PostPosted: Fri Nov 20, 2015 2:02 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

ALIKA T3 wrote:
Dang, they look new Shocked Shocked

When you take your van apart again, replace these front outer cv boots, they will not last at all. You need the thermoplastic ones like the originals (VW switched very early on from rubber to plastic).

Van Café and other vendors carry the correct ones made by GKN Löbro Wink (exact same as white VW's but now black).

Cheers!


Thanks ALIKA
I will look in to that. I'm planning on redoing the German shafts in the future.
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87vanwes
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PostPosted: Sun Nov 22, 2015 2:41 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

The syncro tranny is always a big gamble when buying a doner vehicle and even though I have driven this one quite a bit with no issues it still doesn't mean I'm out of the woods.

For the tdi I need to change the ratios and opted for the 1.09 third and the .70 fourth.

I'm trying to do as much at home before I take the van to my shop.

Pulled the trans fun fun. Lots of falling debris safety glasses are a must. Boy do I miss a twin post lift.
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This thing has not seen the sun in a while. Notice the home made gasket under the low gear housing.. Not good. So now I know someone has been inside this box and that can be a good thing or a very bad thing.
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The locker was disabled with a hose clamp
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This is not bad at all in my opinion.
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And the oil looked good as well.
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So now for lots of wire wheeling. I want it as clean as possible for the disasembaly.
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Clutch arm
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Removed the nose cone. It looks good but this doesn't mean much.
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Doing a few thins on the floor. My engine stand is at the airport but I just gotta know a few things.
Reverse gear has seen better days butt is not a deal breaker. This may explain the magnet or some of it anyways.
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These little c clips can drive you nuts. Some one showed me a long time ago hit two drifts at the same time. I have never looked back.
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Pulling the reverse and low geer slider hub.
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So far every thing looks great.
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So I picked up the stand. I mounted some trans axles like this back in the day. A long time ago. If you have a blown trans with holes drilled in all four ears it wasn't me Rolling Eyes
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This does work very well.
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Pulling the axle flanges
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And the ring gear bearings
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The gears look great. Always good news.
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Getting close.. Just removing all the small bits.
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This was a big relief it all looks great.
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So happy days.. I'm thrilled so far. There is no damage and no wear to speak of the low gear housing looks good with no wear at the main shaft bearing retaining surface.
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Next stop is my shop and the press. I'm hoping for an updated 3-4 slider hub and much more good news.. Wishful thinking..
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ALIKA T3
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PostPosted: Mon Nov 23, 2015 10:38 am    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Relieved Wink Wink

The paper gasket could be original, some of them I've seen are cut too big on the outer rim .

For the C-clips, I use a pair of springed circlip pliers, only one thing to hold while tapping. Same idea though Idea


Keep the pics flowing Cool
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Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget
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87vanwes
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PostPosted: Wed Nov 25, 2015 2:44 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Time to regear the trans. I picked up some goodys from weddle. The decoupler came from gowesty.
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Pressing out the gear clusters. It looks like it would break this housing but its not to bad.
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First piece of good news an updated 3-4 slider hub. This is a 1986 gear box so it was rebuilt at some point.
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This works good but I still seat them with the press
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See the wrong syncro ring on first gear.. It almost got me..
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And the last push.
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It's nice to have that part all done. I will have lots of parts left over for the next rebuild. I'm only replacing a few bearings and the old syncro rings look brand new.
Next is some work on the housings for a cooling set up and a retaining plate for the main shaft bearing.
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hans j
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PostPosted: Wed Nov 25, 2015 3:37 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Looks like aluminum slugs to press on? I need to start digging into transmissions, but I need practice on 2wd first!
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87vanwes
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PostPosted: Thu Nov 26, 2015 10:31 am    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

Hey Hans
That is a piece of aluminum it's great to protect the shaft and also gives some grip. I've seen some things fly out of the press so I respect the power or this tool.

I think you should go for it on the trans it just requires discipline and attention to detail. There are folks who will tell you to steer clear. I'm not cut out that way.
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87vanwes
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PostPosted: Fri Nov 27, 2015 4:16 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Time for some gauges I went from one end of the gauge posts to the other there are some great ideas there. Even though this is a conversion I love the stock look for the most part so I really didn't want to mess with the dash.

I decided to go in the overhead with the ac duct from the tin top and plan to run air to it from the rear ac so here we go.
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It does have its issues.
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I was lucky in life that I was taught to learn from all of those willing to teach and blessed to have been surrounded by so many of them. living on the outer banks we have some great boat builders and I was fortunate to have been around them. So I did learn the art of fiberglass.
We start with the tools of distruction.
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You want to get all the edges sharp as a knife.
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It's all about molding when it comes to fiberglass. It can be done free hand but mold if you can. This is a simple piece of house flashing.
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I'm simply going to glue it on.
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And the wonderful west systems machine.
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Simply wet out the part with a brush and start laring the cloth. I'm going with eight lares of finish cloth.
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On the broken corner I made a simple mold out of making tape and cut some cloth in to strands with a pair of scissors.
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Then I cut a piece hard wood and glued it in to reinforce the face. I may do some sort of a fold down TV.
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Off with the mold.. It stuck so good it pulled the paint off the aluminum.
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Now it's sand and brush on more reson and sand again.
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I love this eastwood plastic restorer. It is meant for black plastic so I decided to see if it would do a color change. Multiple thin coats. It seams to work fine and looks good.
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Wired up some LEDs for the gauges.
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They light up and dim nicely and I did add a light from the tdi golf. I salvaged all the light fixtures from the MK4.
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One more part ready to go when that time comes.... FINAL ASSEMBLY
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You may nave noticed the picture quality got better toward the end. I finally joined the real world and picked up an IPhone even though I said I never would so we will be phasing out the iPad photos. There will still be some.
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0cean
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PostPosted: Fri Nov 27, 2015 5:49 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Great work, looks really nice. Did you paint the sun visors?
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Cluster Rebuild:
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(Number of Different Donor VW Vans Body Parts Used: 12)
(Number of completely different vehicles parts used: 3)
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Signalocity
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PostPosted: Fri Nov 27, 2015 6:12 pm    Post subject: Re: 87 Westy Syncro ALH TDI conversion ~ lots of pics Reply with quote

87vanwes wrote:
Signalocity wrote:
Coming together nicely, well done!


Thanks Signalocity, that means a lot coming from a guy like you.
Your work is spectacular and a tough bar to keep up with.
I always look forward to new posts from you on yours.

It's good to here from a fellow tar heal. Maybe we will cross paths one day.


Thanks, and OBX is on the short list for a test trip, so sure!
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87vanwes
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PostPosted: Sun Nov 29, 2015 9:26 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

0cean wrote:
Great work, looks really nice. Did you paint the sun visors?


Thanks.. I did the visors with the same resurfacer. I was surprised the eastwood stuff was a perfect match to the original black label on the passenger visor.
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87vanwes
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PostPosted: Sun Nov 29, 2015 10:55 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Now for one last job before trailering to my shop....THE SYNCRO GAS TANK..

I've read several say this is a real pain in the.. Well you know.

The thing bit me right out of the gate. I hadn't even gotten the filler out.
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I'm going to predict that there will be some welding or making a new one.
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The tools for the job. I did not anticipate the rust shower there should be a face shield in the picture.
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Stealing gas from a syncro is a piece of cake.
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I left the engine in so I can sell it. All I need is to bolt on my old bell housing and the starter and she will run hanging right there.
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The PO put on brand new amc heads.
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If anyone would have shown up in the middle of this and asked for the van...
I would have given it to them...
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And it's out. The three foot long stainless bolt saved me on this one.
The strange things I keep around.
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On to a trailer and off to the shop.
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Her new parking space. It's going to get ugly from here.
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There is one part I need from the westy to get started cutting the doner van.
A template for the gas filler. I took the side marker as well. They are further back on a syncro.
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And it's out. The round corners are for welding, it's much easier. The white streaks are from osfo. I treat the bare metal every so often.
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Next is the steering rack, front trans mounts and various other syncro specific parts. I still have not drilled and tapped the trans cases. I'm waiting on some parts.
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fleet_maintenance
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PostPosted: Sun Nov 29, 2015 3:45 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Looks like you're off to a great start! Thanks for taking the time to document the progress. If these early posts are any indication, you have the technical side of this project well in hand. It is great to see the fab work involved in re-purposing/retrofitting the AC chase for gauges.

Keep doing work (and posting it) like you have been and I have a feeling that this could turn into one of the "great" build threads that are talked about here (in hushed tones) for years.
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87vanwes
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PostPosted: Mon Nov 30, 2015 2:44 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

fleet_maintenance wrote:
Looks like you're off to a great start! Thanks for taking the time to document the progress. If these early posts are any indication, you have the technical side of this project well in hand. It is great to see the fab work involved in re-purposing/retrofitting the AC chase for gauges.

Keep doing work (and posting it) like you have been and I have a feeling that this could turn into one of the "great" build threads that are talked about here (in hushed tones) for years.


Thanks for the very kind words..

I decided to share my build because all the ones on here have been a huge help to me and pictures were my favorite part. I found them to be very helpful and wanted to share mine so I could possibly help others.

The posts will continue. Some of my favorite threads never finished so I will try not to do that.

Cheers
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Farfrumwork
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PostPosted: Mon Nov 30, 2015 3:20 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

I'll echo the response theme - great work!!


I love seeing others approach to conversions and restoration work. As I completed my own syncro conversion myself, I like seeing how others handle the various little things. I know there are a few things I would do differently if I were to do it again (and I would do it again if I had to or the right opportunity came along).

My donor syncro fuel tank looked about the same Shocked (but my metal filler tube was in much better shape... funny how rust attacks, not so consistent)

Can't wait to see more!
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87vanwes
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PostPosted: Sat Dec 05, 2015 10:11 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Thanks FARFRUMWORK Rust has its own mind that's for sure.

Now for some more trans work. I really want to get this done before moving on to the donor van.

I decided to go with a flywheel driven tachometer.
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Looked all over the bell housing for a good spot but with out any luck.
So I decided on this spot since there's no other spot with some meat and a flat spot for drilling and tapping.
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Off to the welding room for some building up the aluminum.
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I added a lot of material here to create a flat area and some meat for drilling and tapping. This thing was hot so I moved on to the gear carrier housing while it cooled down.
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Drilled and tapped for the cooled gear oil to poor on top of fourth gear.
I'm going with a simplistic cooler set up. Check out ALIKAS trans thread if you want to see an elaborate set up. He has done a great job with it and there's tons of great info as well on syncro transmissions.
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Tapping for my bearing retainer plate.
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Now for some grinding and sanding.
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Mounted the low reverse housing in the milling machine to make room for my retaining plate.
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After a long day at the shop back at home for some final assembly.
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This is the retainer plate I made and why I milled the adjoining housing.
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One of the South African oiling plates installed.
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And a look with fourth gear mocked up next to it
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One more trip to the shop to press the gear cluster in to the housing.
The tie wraps keeps the gears from turning keeping the fourth idler gear from sliding down.
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Some heat on the housing and it drops right in then a couple good whacks with a dead blow hammer.
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Torquing the pinion nut twice.
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Now the low and reverse gears and shifting fork.
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And the housing slid right on.
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I have safety wired in some tough spots over the years. The lower bolt on the plate was a hard one.
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Setting the back lash and bearing preload.
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On with the bell housing.
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The tach sensor turned out not to bad.
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And I have a complete transmission again. Laughing Laughing
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87vanwes
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PostPosted: Sun Dec 06, 2015 8:49 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Funny how I just finished putting my tranny back together and then found this in my mail box. A card from Weddle.. These guys are great and a pleasure to do business with. At one point or another I do need to give credit to all the vendors who help me make this build possible.
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87vanwes
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PostPosted: Sat Dec 12, 2015 6:14 pm    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Friday afternoon I went to the shop to tackle a part of this project that I had to get out of the way Crying or Very sad

Taking out the syncro specific parts...

I started by removing the front suspension that I had restored early on. If you are curious how I did this I covered it in the beginning of this thread.
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Very dusty and dirty after a several months in my drive way and now in the shop. This is a dusty place between metal fabricating and powder coating.
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This is not going to be fun. I need to remove the parts that hold the steering rack and the trans mounts.
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Now I am very methodical and that is wishful thinking. Reverse assembly is key. So I thought...
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After digging through 30 years of dirt, rust, grime and VWs waxing (which was good by the way) I found all the spot and surface welds and attacked them.
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Some I chose to cut away and deal with them on the bench.
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Enough for today I will get back at it tomorrow .
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I knew this would be a tough day but the show must go on. Notice the corner cut off of the box that's under the drivers seat. This is a syncro specifics feature. It is done on both sides for suspension articulation to prevent the tires from hitting the boxes.
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And then my best friends daughter shows up to take a photo of the misery.
So I took a picture of her taking a pic of me.
He's hunting and fishing in WV and I'm not.
I wanted to go but I had obligations at the airport.
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I got the steering rack mounting out and went after the trans mission cross member.
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I did not take a single photo of the cross member removal. This thing had some meat holding it in. There was a blue tip adjustable wrench and a plasma cutter only feet away but I stuck it out.
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A couple of pics of the chassis with the parts removed. Notice I cut out the little hump to clear the drive shaft. I do not have a rock solid plan for the trans mounts. I haven't seen much on how others have addressed this. I am open to opinions.
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The only thing left for today is to get the gas filler components.
I took the template of the westy and traced it out on the donor van.
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Then cut it out a little larger than the template. I will tune it up with the belt sander for a tight fit. The plan is to tig and mig weld the entire length of the cut. The beauty of this is both sides of the panel are readily accessible for treatment. Raw welds are rust magnets.
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I have had enough for the day. The beer light came on at about 2 which is early in my world. The buzzer came on at 5 so I must silence it. I'm going to move this van outside and get the westy here soon. There is a ton of cutting to be done there.
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CHEERS.....
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snwbrdr435
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Joined: August 10, 2013
Posts: 337
Location: North Of Boston
snwbrdr435 is offline 

PostPosted: Sun Dec 13, 2015 7:06 am    Post subject: Re: 87 Westy Syncro TDI conversion and restoration~lots of p Reply with quote

Awesome work!
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