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7 seater Caravelle Syncro to camper
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vik
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PostPosted: Wed Nov 04, 2020 11:31 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

pnwkayaker wrote:
Vik, do you have any more information about the rear bench (manufacturer, how to obtain it, how it was installed) ?

It has the integrated shoulder belts attached to the bench, which will eliminate the need of cutting a slot on the rear cabinet (which the GW instructions ask you to do to use their kit with the rear mounting points).



It is from M1 beds from UK.
Seat itself is mounted trough floor with 4 srews and steel plate under the floor.
Belts are integrated in the structure of the bed itself.

It will be for sale soon, but I don't know how interesting this will be for anyone from US/CA due to shipping cost

Benefits
- no need to cut holes in cabinets
- OK design wise
- can mount a toddler seat without problem

¨Minuses¨
- due to the seat belts I have to always lift the rear cushion when folding the seat (probably will fit T2 as well)
- it is not as wide as westy seat
- it is not using VW mounting points
- it is not as spacious under the bank as westy seat
- in case of many items over the engine the seat retraction might be compromised...

I managed to buy original westy seat (don't ask me how much I paid for it Sad ) and hope to swap them this winter. But it means cutting few cms from the installed cabinets Sad
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pnwkayaker
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PostPosted: Wed Nov 04, 2020 11:57 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Thanks for the feedback!
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vik
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PostPosted: Thu Nov 12, 2020 7:15 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Just a quick update before more stuff is going to happen Wink

Fresh set of Trailmaster +40mm lift springs and shock installed.
Image may have been reduced in size. Click image to view fullscreen.


There is never ending debate what combination is best and I did not found any particular reports of these being wrong in any way.
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vik
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PostPosted: Fri Jan 01, 2021 7:12 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Happy new year

First small piece of the puzzle is ¨new¨ instrument cluster. Gone are the analog clock as much as I liked them I really missed the tachometer. I managed to source petrol cluster from unknown year (it turned out it is 86 or older) with minor damage, foil was gone and not working clock (I forgot to get LCD before all closed down).
This time the repair was somehow more hassle than the original one. 3D print to the rescue.
Image may have been reduced in size. Click image to view fullscreen.

It looks, well stock Very Happy
Image may have been reduced in size. Click image to view fullscreen.

Foil was replaced by Slowbridge kit. Kai was kind enough to add for me LED for my check engine light.
Best on all of this is that these older tachometers work directly with the Subaru ECU signal so no need for converters or modifying the PCB.

BTW: What was the green light located in the left upper corner originally for?
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4Gears4Tires
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PostPosted: Fri Jan 01, 2021 7:28 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Blinkers
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vik
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PostPosted: Mon Jan 11, 2021 3:59 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

I managed somehow to finish the cut of the travel movie.


Link


Hope you will like it as I see a lot of space for improvements.
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vik
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PostPosted: Tue Apr 27, 2021 8:46 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Well, the the good news is that new drivetrain is ready to be installed in my Syncro. The bad news is that still it will take a while.
Image may have been reduced in size. Click image to view fullscreen.

On picture above you can see rebuild front diff with locker (ADH) and refurbished VC.
On the gearbox side the main difference is 4.86 crown and pinion and .74 4th gear. ALL bearings are new (Vantopia) front and rear along few synchro rings and Aluminum bearing plate.
PO managed to knocked off the locker sensor including bit of the Magnesium gearbox case. This was repaired and now I will have working sensor as well Very Happy Powerflex bushes F+R are in place as well.

This all took obviously longer than expected (covid, brexit...) but can not wait to get to down from 4140rpm to 3230rpm (calculated) @120km/h

Electrical department: Due to modifications in the interior (I managed to source Westfalia 2/3 folding seat) which I needed to get again 4 seats capacity in I will need to cut about an inch from the cabinets. When I have seen how ¨professionals¨ made the installation I wanted to cry. No battery cut off switch, no solar cut off switch. All cables were like spaghetti. So I made a drawing of the installation how it shall be done:
Image may have been reduced in size. Click image to view fullscreen.


Engine department:
Heads shall be back this week from rebuild.
I have new crank, pistons +25, rings, oil pump, bearing, STI conrods, head bolts and block bolts.

When all of this is out the fuel tank is on its way out as well to be resealed and to see if there is any corosion on the body there. Just to find VDO fuel level sender is not possible at the moment.

Sometimes I feel like a Sisyphus. Rolling Eyes
I just want to get in the bus and DRIVE it and ENJOY it
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vik
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PostPosted: Thu May 06, 2021 3:40 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

May I ask if anyone has installed the Powerflex from Heritage Collection?
I ordered few bushes and I was expected classic yellow/purple. I'm sure they will be much better than what I do have at the moment. Just asking...

Image may have been reduced in size. Click image to view fullscreen.


Powerflex don't provide too much info if they are more or less stiff. I quote:
The Powerflex Heritage Collection of bushes has been chosen specifically for your modern classic vehicle.

Manufactured using modern day materials with properties biased for the road, these dark grey coloured bushes will restore, compliment and improve any collector's car, whilst retaining the same standard appearance of a regular rubber bush.

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vik
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PostPosted: Sat Sep 25, 2021 12:15 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Recently I had lot of bad luck. My block is stuck 6m in a reputable workshop for honing and still not done. I almost already picked it up when trough a friend an offer for new shortblock was delivered to me. The offer was too hard to resist. Heads are already overhauled so I said yes.
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Next week I expect to see it in the back of my bus.
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djkeev
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PostPosted: Sat Sep 25, 2021 4:36 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

A new short block is a beautiful thing!

Dave
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vik
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PostPosted: Thu Sep 30, 2021 12:18 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

I can not agree more with that statement.

Heads after the rebuild
Image may have been reduced in size. Click image to view fullscreen.

What I found sad that the donor car had not that high milage, but they had all valve stem seals gone. All valve seats were grinded too.

Head desiign is interesting for me - SOHC, but 16V Very Happy

Another interesting part might be airbox. In US there are several options available. I had cone cotton filter which I hated
- noisy
- it suck in hot air
In Germany there is company Zanzinger motorsport (I found them almost by an accident) and they have stainless steel bottom part of airbox and uses Subaru upper airbox type (there are 3 versions available). All located on common left side as most Subaru conversions. I do have intake to the righ side and want to utilize WBX cold air snorchel so they modified it to fit the airbox up side down. The elbow is 3D print I designed (V1) from ABS. I might add some ribs if needed. But it seems super sturdy.

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vik
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PostPosted: Wed Aug 31, 2022 12:08 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Project is alive...
I gave up promises and exuses why they do not have a time and rented a lift in a garage. I get a hand here and there, but so far most of the work was done by me.
As the engine is still out of the car - but completed with sensors, water etc. installed and mated with a transmission I ordered new slave clutch cylinder and install it.
Image may have been reduced in size. Click image to view fullscreen.

As well installed upper balljoint spacers from Busman to get the geometry corrected.
Image may have been reduced in size. Click image to view fullscreen.


It seems that the list of work is only getting longer regardless the work done.
Tomorrow I hope to get the fuel tank out, clean body behind it and reseal everything.

Question: Shall I get new fuel level sender?
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kevinm
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PostPosted: Wed Aug 31, 2022 12:48 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Looks great, Vik. Congrats!

Q: is the clutch slave cylinder installed backwards? I thought it should be oriented with the hose connection facing the front of the vehicle.

- Kevin
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vik
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PostPosted: Thu Sep 01, 2022 11:59 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

kevinm wrote:
Looks great, Vik. Congrats!

Q: is the clutch slave cylinder installed backwards? I thought it should be oriented with the hose connection facing the front of the vehicle.

- Kevin


Hi Kevin
Great observation. Problem is, that it sit for a while. The old cylinder was still mounted in this position. So I guess it is correct. Bentley shows reversed direction, but many pictures I could find on syncro gearboxes shows this orientation as well.

Today I managed to reseal the gas tank. Rust behind is not as bad as I expected.
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While I resealed the tank I found this:
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PO probably did not has access or did not want to buy new rings.
Similar story on fuel filler pipe
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As the ¨original¨ pipe has been butchered I´m not 100% sure about the orientation of full pipe. If anyone can post a picture how it sits behind the shock it will be grand.
This is probably up side down Rolling Eyes
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PostPosted: Thu Sep 08, 2022 11:11 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Hallo all,

Another day in the workshop and again there was a surprise waiting for me.
But the good stuff first. Something is back in the bus Very Happy

Image may have been reduced in size. Click image to view fullscreen.

Original Westfalia seat and seatbelts. Front handbrake cable has been replaced by original VW heratege part and front driveshaft has new outer CV boots. Pitty that the aftermarket quality is not really up to the OEM standards. I can see to do this again Rolling Eyes

Anyway after this I started to install Powerflex bushings related to the anti roll bar I do have. The difference between standard and the more beefy one from Brickwerks/Einbach is interesting
Image may have been reduced in size. Click image to view fullscreen.


And than come big relevation why my Bus was driving like a snake in highway speed and cross wind condition. PO did some repair/mod on the Anti Roll Bar drop links (both). They were broken in the past and a srew was welded to the end. BUT it had higher diameter than standard so the steel bushing was not present. Try to find 10 difereces:
Image may have been reduced in size. Click image to view fullscreen.


I was lucky as local specialist had refurbished (zinc plated) units available. I took them with the stainless washers.

Next week plan: Get the steering rack reseal finished and reinstall complete front end of the car -> driveshfts, rack, new diff with a locker.
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PostPosted: Fri Sep 16, 2022 10:18 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

Dear coleagues (if anyone is watching this).
There was a thread with a name similar to ¨mania deepens¨ and this is how I do feel right now.
You touch one problem and 3 additional problems knocs on your door.

We wanted to reseal the power steering. The onle repair set available
- do not contain all rubbers and teflon washers
- ¨main rod¨ had rust on
Solution: New steering box. And it is back on the car now
Image may have been reduced in size. Click image to view fullscreen.

When I was there I wanted to verify how the steering shaft couplers looks like:
Image may have been reduced in size. Click image to view fullscreen.

Bed (Original VW part) so they have been replaced with part available now:
Image may have been reduced in size. Click image to view fullscreen.

I actually do not feel great as I know the quality is not the same.
Next job: Change the front windschield seal.
Image may have been reduced in size. Click image to view fullscreen.

And it resulted in finding holes
Image may have been reduced in size. Click image to view fullscreen.

Solution - get a repair panel
Image may have been reduced in size. Click image to view fullscreen.

BUT There might be light on the end of the tunnel. I just hope it is not a train Wink
Wheels (I hated the original color) and engine carrier which was discusting and slightly getting rust shade are back from powder coating
Image may have been reduced in size. Click image to view fullscreen.

And it looks splendid

I do hope to get some good news next week. It have to get worse before it gets better, right?
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dobryan
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PostPosted: Fri Sep 16, 2022 11:05 am    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

And down that slippery slope you go! But you'll have it all done when you are finished.

I am not one to talk. All my buses seem to get torn apart and rebuilt...
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PostPosted: Fri Sep 16, 2022 12:13 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

vik wrote:
As the ¨original¨ pipe has been butchered I´m not 100% sure about the orientation of full pipe. If anyone can post a picture how it sits behind the shock it will be grand.
This is probably up side down Rolling Eyes
Image may have been reduced in size. Click image to view fullscreen.


Just saw this post. Here's the best pic I have of the filler pipe on the Syncro.
Note the dimple in the pipe for extra clearance to the shock. Hope this helps.
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Fri Sep 16, 2022 5:17 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

I will also say, early filler pipes had the tab screwed into the chassis beam (down).
Then I think starting 87 they changed to have it screwed into the sheet metal, up.
I prefer the early version.
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PostPosted: Fri Sep 16, 2022 11:10 pm    Post subject: Re: 7 seater Caravelle Syncro to camper Reply with quote

thx for the info regarding the pipe.
My bus is 87 so it may suit my car as well. Funny thing is that there is no mounting hole anywhere...
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