VW Syncro Westfalia - Build Log with Pics

[Hodakaguy]

Originally Posted by Sniper X

How much more HP and TQ does the Subaru motor have over the stock motor?

Stock 2.1 Wasserboxer. HP: 90. Torque: 117

06 Subaru 2.5L: HP: 175. Torque: 169

Plus the Subaru gets better MPG....20mpg

Hodakaguy

[atadloco]

Cool Syncro!! I'm following this on thesamba as well. I have an 83 Westy that eventually I want to go the 2.2 or 2.5 route, the challenge for me is mine is air cooled to start.

[Sniper X]

Originally Posted by Hodakaguy

Stock 2.1 Wasserboxer. HP: 90. Torque: 117

06 Subaru 2.5L: HP: 175. Torque: 169

Plus the Subaru gets better MPG....20mpg

Hodakaguy

Sa Weet! That should be quite the ticket for a more pleasurable driver and better eco always helps! Cool thread, you certainly have a lot more patience than I do for a total swap!

[Hodakaguy]

Originally Posted by atadloco

Cool Syncro!! I'm following this on thesamba as well. I have an 83 Westy that eventually I want to go the 2.2 or 2.5 route, the challenge for me is mine is air cooled to start.

I believe that most of the mounts etc are there for the cooling system etc that needs to be installed.

Hodakaguy

[Hodakaguy]

Originally Posted by Sniper X

Sa Weet! That should be quite the ticket for a more pleasurable driver and better eco always helps! Cool thread, you certainly have a lot more patience than I do for a total swap!

This build/swap is quite a bit more complicated that just a engine swap since I'll be doing a bunch of other stuff while I'm in there. My goal is a super reliable westy when I'm finished. If a part is in doubt or needs to be touched I'm going to try and get to it while it's all apart....don't want to go back in any time soon once it's all together.

Hodakaguy

[DireWolf]

Synchros give me the hornies.

[kobudo28]

Originally Posted by DireWolf

Synchros give me the hornies.

They make your tranny shift more better too.

Enjoying this build thread.

I spent a fair amount of time in an air cooled Westy as a young man. They didn't go very fast so "fair amount of time" is a relative thing. We took one to Lyme Rock, Maine and out to Watkins Glenn and a had a blast.

[Hodakaguy]

Time to clean up a few parts. I friend of mine has a powder coating oven/setup that works great so I borrowed it for this built. I'll be powdercoating all the small pieces, brackets etc before re-installing them on the bus.

Here's a link to our last powder coating adventure on my friends BMW GS motorcycle...It was a fun project that kept growing in scope as we went...came out very nice. Link Here:http://www.advrider.com/forums/showt...ight=hodakaguy

With the help of mike we brought the PC oven to my house. Not Light!




Woke up early this am and ran into work to sand blast the parts. Minor pitting from surface rust but the parts are in really good cond. All cleaned up and ready for powder coating.




One of the spot welds had come loose on the tab that holds the fuel pump in place. With the parts cleaned up now is the time to fix it.

Picture of my ugly mug getting ready to re-weld the fuel pump mount.




Welded and ready to be powder coated.






Prepping the cross shaft arm for PC. The tape is a special high temp tape that you can use in the oven. I left the tip of the ball clear of PC and will lubricate well during install.




Parts baking in the oven...385 deg F. for 19 min. We use Columbia Powdercoating powder and really like their MiniTex black. It's a fine textured satin black that is UV stable and holds up very well to scratches etc. I'll be doing all the parts in MiniTex.




Pull the parts out of the oven...let them cool down and they are ready to bolt up. No waiting for paint to dry!

Here's the parts fresh out of the oven, ready for years more of service.






There will be lots more powder coating to come....Soooooooo much to do!

Hodakaguy

[Hodakaguy]

Originally Posted by kobudo28

They make your tranny shift more better too.

Enjoying this build thread.

I spent a fair amount of time in an air cooled Westy as a young man. They didn't go very fast so "fair amount of time" is a relative thing. We took one to Lyme Rock, Maine and out to Watkins Glenn and a had a blast.

I'm really looking forward to camping trips in the bus....can't wait!

Hodakaguy

[rider1150gsadv]

Sweet write up! I remember the thread with the GS too, that was a nice project you did..

[Keith]

Great thread, keep the pics coming!

[Hodakaguy]

Thanks. Here's the latest progress report.

Started on the suspension today. I want to get the suspension finished and back on the bus before dropping the fuel tank, I just don't like being under the bus while it's up on jack stands.

Well here goes....




And the right rear is off






With temps in the 90's the operation is moved into the shade beneath the tree. All parts are placed in labeled zip lock baggies, makes it easy to keep track of parts.




Bearings have a little bit of play and a rough sound to them...new bearings/seals will be installed.




All taken apart. Now time to get the bushings out.

A vise, a socket and a piece of tubing worked great to remove the bushings.




Now to get the sand blasting out of the way....ugggg




Parts sand blasted and ready for powder coating. No energy or time left today....start again in the am.




Hodakaguy

[award900]

Lurk.

[kobudo28]

I really like the completness of your approach; take it apart, fix, update, paint everthing you touch and make it a complete, more reliable and better ride when you are done. Very nice atttention to detail! It is clear you take pride in your work.

Wrenching Smiley now please!

[dlearl476]

Something tells me that when you finish with this one, you're going to want to do another one with all the information you've learned from this one, what do do again, what to avoid, etc.

I'd be happy to help finance the next project by buying this one when you get it finished.