VW Syncro Westfalia - Build Log with Pics - Page 3

Mambo Dave · 06-27-2012, 06:21 AM

Quote:

Originally Posted by Hodakaguy

It's really not as bad as it looks, I'm 6'1" tall and I can use the kitchen without a problem. I carry a Jet boil in one of the cabinets for heating water...a lot faster if you only need hot water.

Hodakaguy

Cool, thanks - then it would work for me.

Hodakaguy · 07-01-2012, 04:16 PM

Work around the house has slowed progress on the Westy.

I did manage to get a little work done on the 2.5L this weekend.

Received my parts for the timing belt change out in the mail on friday, decided to do a little work on it early Sat morning. The engine only has 60K miles on it but since it's out of the vehicle and on the stand it makes since to freshen everything up while it's easy to get at.

Timing belt removed.

New water pump installed.

New idlers, water pump, thermostat, timing belt and belt tensioner installed.

Note the red arrow, this is where the timing belt guide would be if this engine came out of a manual transmission car. The guide keeps the belt from skipping a tooth if its parked in gear on a hill without the E-brake. Since this engine came out of an automatic Outback it doesn't have the guide, Since I will be installing it in a manual Vanagon I will install the guide before I button it up.

A shot of the guide as listed in the Subaru repair manual. The part is only $5.00 and I figured the Japanese installed it for a reason, I'll install it on mine for cheap insurance.

Old parts.

A few more bits showed up for the build. Received the front and rear wheel bearings, hardware and seals. Also received the Burley upper control arms and T3 Powerflex suspension bushings.

Once I start on the suspension I'll sand blast all the parts and powdercoat them while they are out, should make a clean install once re-assembled.

Can't wait!

Hodakaguy

zgfiredude · 07-01-2012, 06:07 PM

Looking good, sub'd and watchin' every step of the journey!

madeouttaglass · 07-01-2012, 06:43 PM

At first I wondered why screw up a nice original Syncro, but it looks like you do very nice, thorough work. This is going to be a nice build.

.fisher · 07-01-2012, 06:56 PM

Quote:

Originally Posted by zgfiredude

looking good, sub'd and watchin' every step of the journey!

+1!

Cogswell · 07-01-2012, 07:09 PM

Looks like an interesting build to me too,

IN !

Mike

Brtp4 · 07-02-2012, 10:04 PM

In for a very cool project.

BP

huzar · 07-03-2012, 09:04 PM

a1fa · 07-04-2012, 05:48 AM

Belts, due to tension, or lack there of, are known to pop out... Good $5 insurance in my opinion.

Hodakaguy · 07-21-2012, 08:13 PM

Ok...Finally go the new driveway poured so the Syncro build can resume. I will be pulling the stock engine soon, lots of work ahead.

I've made a few small steps....hopefully the pace will pick up now.

Tightening the crank pulley. You need clean oiled threads and it needs to rotate at least 60 deg before it gets full torque. Mine went past 90 deg and finally hit torque. Here's a shot tightening the crank pulley.

Installing the reverse coolant manifold. With the intake manifold removed you can see the stock coolant manifold. The modified manifold will exit the engine on the back side instead of the front...making for a nice clean install in the bus.

Here you can see the modifications done to the stock coolant manifold. This manifold is from RMW. There is deep corrosion pitting where the coolant hose connects to the manifold on the RMW supplied unit...the core I'm sending them is nice and clean :? . I will clean up the RMW unit and fill in the pits with metal filler, don't want any leaks at the hose connection.

Lots of parts :-)

Had a lighting storm pass over a couple days ago, I drove the Westy to a vacant lot and tried to frame the bus in with a lightning bolt...unfortunately the lightning stopped right as I got set up :-(

The engine coolant sensor harness needs to be modified to reach the new sensor location. The blue arrow is where the original sensor port was located...the red arrows are where the harness needs to reach now. Here I've started to lengthen the stock harness.

Harness modified :-)

Hopefully more progress will be made soon.

Hodakaguy

nfranco · 07-21-2012, 08:21 PM

What kind of metal filler can you use on the coolant manifold?

Hodakaguy · 07-21-2012, 08:47 PM

Quote:

Originally Posted by nfranco

What kind of metal filler can you use on the coolant manifold?

Any kind of metal epoxy will work...just fill in the pits and sand smooth. They manifold was pressure tested before it was shipped to me, I'm just concerned that coolant will try to leak out between the hose and the manifold if the pits are left in place.

Hodakaguy

nfranco · 07-21-2012, 09:34 PM

Cool, thanks. I've got an old Land Cruiser with some pitting on the thermostat housing, will give the epoxy go.
Great build on the Westy!

Quote:

Originally Posted by Hodakaguy

Any kind of metal epoxy will work...just fill in the pits and sand smooth. They manifold was pressure tested before it was shipped to me, I'm just concerned that coolant will try to leak out between the hose and the manifold if the pits are left in place.

Hodakaguy

a1fa · 07-22-2012, 06:16 AM

Hoodka, does your horn work?

Hodakaguy · 07-22-2012, 06:39 AM

Quote:

Originally Posted by a1fa

Hoodka, does your horn work?

Yes.

Hodakaguy

07-01-2012, 04:16 PM	#32
Hodakaguy ^OP NorthWest Adventure Rider Joined: Jul 2007 Location: Eastern WA State Oddometer: 1,680	Work around the house has slowed progress on the Westy. I did manage to get a little work done on the 2.5L this weekend. Received my parts for the timing belt change out in the mail on friday, decided to do a little work on it early Sat morning. The engine only has 60K miles on it but since it's out of the vehicle and on the stand it makes since to freshen everything up while it's easy to get at. Timing belt removed. New water pump installed. New idlers, water pump, thermostat, timing belt and belt tensioner installed. Note the red arrow, this is where the timing belt guide would be if this engine came out of a manual transmission car. The guide keeps the belt from skipping a tooth if its parked in gear on a hill without the E-brake. Since this engine came out of an automatic Outback it doesn't have the guide, Since I will be installing it in a manual Vanagon I will install the guide before I button it up. A shot of the guide as listed in the Subaru repair manual. The part is only $5.00 and I figured the Japanese installed it for a reason, I'll install it on mine for cheap insurance. Old parts. A few more bits showed up for the build. Received the front and rear wheel bearings, hardware and seals. Also received the Burley upper control arms and T3 Powerflex suspension bushings. Once I start on the suspension I'll sand blast all the parts and powdercoat them while they are out, should make a clean install once re-assembled. Can't wait! Hodakaguy __________________ NV 2012 - In Memory of the Crewmen RR: CLICK HERE Adventure Is Out There - NV RR: CLICK HERE Riding Through History - NV RR: CLICK HERE And Then There Were Four - OR RR: CLICK HERE My VW Syncro Westy Build Thread: CLICK HERE

07-01-2012, 06:43 PM	#34
madeouttaglass The AntiHarley Joined: Mar 2009 Location: Bristol Hills in the Fingerlakes region of NY Oddometer: 2,186	At first I wondered why screw up a nice original Syncro, but it looks like you do very nice, thorough work. This is going to be a nice build. __________________ Our ride across the USA on a Ural Gear Up- http://www.advrider.com/forums/showthread.php?t=781149

07-01-2012, 07:09 PM	#36
Cogswell Spudly Adventurer Joined: Jan 2005 Location: Riding with my pal Richard Cranium Oddometer: 3,253	Looks like an interesting build to me too, IN ! Mike __________________ Cogswell Rides To Big Bend See my airhead project here Time Warp Vintage Motorcycle Club The good thing is, your damn motor can't read. If it says oil on the container, it's pretty much OK to dump in there.... ED.

07-02-2012, 10:04 PM	#37
Brtp4 Yea, its a friggin L Joined: Sep 2006 Location: Bend, OR Oddometer: 1,759	In for a very cool project. BP __________________ BP Atomic Moto.com Bend, OR

07-03-2012, 09:04 PM	#38
huzar Pastor of Muppets Joined: Aug 2009 Location: Bellevue, WA Oddometer: 1,448	__________________ Marcin 2009 Suzuki DL650A \| 2008 Husqvarna TE610 Chasing Hewby around Peru \| An airhead chasing a blonde through through Tasmania

07-01-2012, 06:07 PM	#33
zgfiredude Gnarly Adventurer Joined: Nov 2009 Location: Aspen, Colorado Oddometer: 493	Looking good, sub'd and watchin' every step of the journey!

07-04-2012, 05:48 AM	#39
a1fa Riding Nomad™ Joined: Nov 2006 Location: Arkansas Oddometer: 12,718	Belts, due to tension, or lack there of, are known to pop out... Good $5 insurance in my opinion. __________________ Learn to ride. Ride to learn. FS: 1993 Suzuki DR350S (wide ratio 6 speed - street legal kickstart)

07-21-2012, 08:13 PM	#40
Hodakaguy ^OP NorthWest Adventure Rider Joined: Jul 2007 Location: Eastern WA State Oddometer: 1,680	Ok...Finally go the new driveway poured so the Syncro build can resume. I will be pulling the stock engine soon, lots of work ahead. I've made a few small steps....hopefully the pace will pick up now. Tightening the crank pulley. You need clean oiled threads and it needs to rotate at least 60 deg before it gets full torque. Mine went past 90 deg and finally hit torque. Here's a shot tightening the crank pulley. Installing the reverse coolant manifold. With the intake manifold removed you can see the stock coolant manifold. The modified manifold will exit the engine on the back side instead of the front...making for a nice clean install in the bus. Here you can see the modifications done to the stock coolant manifold. This manifold is from RMW. There is deep corrosion pitting where the coolant hose connects to the manifold on the RMW supplied unit...the core I'm sending them is nice and clean :? . I will clean up the RMW unit and fill in the pits with metal filler, don't want any leaks at the hose connection. Lots of parts :-) Had a lighting storm pass over a couple days ago, I drove the Westy to a vacant lot and tried to frame the bus in with a lightning bolt...unfortunately the lightning stopped right as I got set up :-( The engine coolant sensor harness needs to be modified to reach the new sensor location. The blue arrow is where the original sensor port was located...the red arrows are where the harness needs to reach now. Here I've started to lengthen the stock harness. Harness modified :-) Hopefully more progress will be made soon. Hodakaguy __________________ NV 2012 - In Memory of the Crewmen RR: CLICK HERE Adventure Is Out There - NV RR: CLICK HERE Riding Through History - NV RR: CLICK HERE And Then There Were Four - OR RR: CLICK HERE My VW Syncro Westy Build Thread: CLICK HERE

07-21-2012, 08:21 PM	#41
nfranco over macho grande? Joined: Jan 2006 Location: la ca Oddometer: 707	What kind of metal filler can you use on the coolant manifold?

07-22-2012, 06:16 AM	#44
a1fa Riding Nomad™ Joined: Nov 2006 Location: Arkansas Oddometer: 12,718	Hoodka, does your horn work? __________________ Learn to ride. Ride to learn. FS: 1993 Suzuki DR350S (wide ratio 6 speed - street legal kickstart)

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