Syncro renovation |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Posted: 22 Nov 13 at 22:54 |
Ive been the proud owner of my VW 1.6TD syncro for about 3 years now, but I've had very few chances to get much use out of it. I was very impressed with the grip while driving up a hill side covered in sheet ice.
Now in need of an mot having been sat for most of these 3 years and I find myself with plenty of work to do. Lots of rust and holes which I guess is usual for a vehicle that is so good for winter driving on snow and ice and the UK road salt. Removing front wheel arch IMG_1232 by ultimate_engineering, on Flickr Rotten B pillar once rear of arch is removed IMG_1234 by ultimate_engineering, on Flickr Rusty lower rear 1/4 Panel. IMG_1235 by ultimate_engineering, on Flickr IMG_1237 by ultimate_engineering, on Flickr IMG_1238 by ultimate_engineering, on Flickr IMG_1239 by ultimate_engineering, on Flickr IMG_1241 by ultimate_engineering, on Flickr New brake pipes through out. IMG_1248 by ultimate_engineering, on Flickr New stainless fuel tank straps fitted. IMG_1246 by ultimate_engineering, on Flickr More photos to follow are work progresses. |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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mrhutch
Moderator Group the ginger princess Joined: 21 Aug 07 Location: Herefordshire Status: Offline Points: 5147 |
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excellent!! watching this Tim..
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T3 1981 Westy Vanagon - thinks lubricant is a fuel
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max and caddy
Vanorak Joined: 12 Dec 09 Location: Lancaster..uk Status: Offline Points: 4866 |
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Power steering I see? Is it rhd? What is it exactly...pics are kinda close up!
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youthy giblets
Vanorak Joined: 29 Jul 11 Location: Darlington Status: Offline Points: 2117 |
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LHD or twin slider? Is it getting the Tdi treatment Tim?
Edited by youthy giblets - 10 Dec 13 at 21:22 |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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LHD with the full steel roof.
Yes tdi but not sure what to do about the gearbox. AHF ratios a rubbish for tdi even with taller tyres, so may end up fitting a UN7 set up from R enault 21 quadra. But this will loose the G gear option.
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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Gtavalanche
Vanorak "I'm learnding" Joined: 22 Feb 11 Location: Ipswich Suffolk Status: Offline Points: 1305 |
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Have you seen the synquat build on the samba. Some talented fella is fitting a counter clockwise 1.8t with quattro running gear. Again loses the g-gear though.
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I taste Hurty!
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max and caddy
Vanorak Joined: 12 Dec 09 Location: Lancaster..uk Status: Offline Points: 4866 |
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Your right, a standard AHF is not good with a tdi...ran mine like that for a week or two and whilst it was quite nippy on country lanes it was no good on motorways and bypasses...a syncro with no g gear sounds like a bad idea...without it off road use would be accompanied by a smell of burning clutch I reckon and could actually be dangerous..handy if you ever have a big trailer on the back as well as manoeuvring in g is a lot more relaxing than revving and juddering like in say a transit. |
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jes*b
Not Quite Newbie Joined: 26 Jul 09 Status: Offline Points: 38 |
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Gotta keep the g gear IMHO
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Gtavalanche
Vanorak "I'm learnding" Joined: 22 Feb 11 Location: Ipswich Suffolk Status: Offline Points: 1305 |
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or use the transmission from an A6 allroad with the low ratio option.
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I taste Hurty!
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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The joy of the UN7 is that the front diff unit has diff lock but I guess that the Audi A6 stuff relies on ABS controlling spinning wheels. More technology to go wrong.
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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To keep things up to date.
I decided to keep the syncro transmission but have taller gears fitted. So now have the taller std 2nd gear shafts and also the tallest 3rd and 4th gear sets fitted. I've change to 16" wheels with 215 70 16 General grabbers so hope to be able to cruise at 60mph without thrashing the engine to hard. I also started cutting the rot out of the van ready for the MOT. I need to get things done here as my panel van is out of tax and mot at the end of the month and I want to replace it with the syncro for the winter. Pictures to follow when I have time to up load. 90hp tdi engine ready to fit, but need to find a good solution to cooling the charge air with the syncro fuel tank in the way of my current solution. |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Some photos of the work so far with the body.
I removed the lower section of the off side panel, behind sliding door. LHD to reveal some rust. No surprise there really. IMG_1243 by ultimate_engineering, on Flickr End closing panel rotton. IMG_1242 by ultimate_engineering, on Flickr After a bit of cutting and grinding IMG_1462 by ultimate_engineering, on Flickr New panels being made and offered up IMG_1465 by ultimate_engineering, on Flickr Rebuilding the sill end closing panel IMG_1467 by ultimate_engineering, on Flickr Weld through primer to slow the rust down on the new metal IMG_1471 by ultimate_engineering, on Flickr Not sure what the box section was meant to look like in the C pillar as the bottom was completely rotten away. So I had a guess at what I thought should have been there. IMG_1475 by ultimate_engineering, on Flickr |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Then on to the rear corner of the bus. Looking toward the back on the off side. More rust and more holes.
Looking up at the panel located behind the off side rear light. More rust. IMG_1480 by ultimate_engineering, on Flickr After unpicking the panels I start to make up replacements in new metal. IMG_1481 by ultimate_engineering, on Flickr IMG_1483 by ultimate_engineering, on Flickr And then on to fitting the new metal IMG_1484 by ultimate_engineering, on Flickr New arch and outer panels fitted. IMG_1496 by ultimate_engineering, on Flickr |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Then on to the front off side jacking point and B pillar.
IMG_1485 by ultimate_engineering, on Flickr Cutting off the front of the off side out rigger to expose the jacking point and the end of the sill. IMG_1487 by ultimate_engineering, on Flickr IMG_1490 by ultimate_engineering, on Flickr From under the van looking toward the front showing the rotten end of inner sill being removed. IMG_1492 by ultimate_engineering, on Flickr Holes made from above to remove spot welds holding the inner sill to the floor. IMG_1493 by ultimate_engineering, on Flickr Jacking point and front end of sill removed. IMG_1494 by ultimate_engineering, on Flickr From the front looking toward the back IMG_1495 by ultimate_engineering, on Flickr |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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bene
Groupie Joined: 07 Jan 14 Location: Gillingham, Ken Status: Offline Points: 96 |
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Great pics and info... cheers!
keep up the good work.
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andylen
Newbie Joined: 31 Jul 09 Location: Swansea Status: Offline Points: 12 |
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Well done Tim
Found your build at last. Will start putting mine on this weekend |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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I will get some more picture on here soon. Plenty of new metal now fitted.
Tim.
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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twisted wheel
Not Quite Newbie Joined: 30 Jul 13 Location: mid Wales Status: Offline Points: 15 |
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Looking good.
Bet it feels nice to make some progress after all the digging/grinding? I'm doing a couple of syncros for people at the moment , one as bad & the other is much much worse than yours! They're all worth saving - keep up the good work! |
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Welding & Restoration Services
07970 827336 https://www.facebook.com/pages/Welding-and-Restoration-Services/254951737969847 |
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Off side B pillar
IMG_1667 by ultimate_engineering, on Flickr Outer B pilar with rebuilt rear of arch going back on IMG_1676 by ultimate_engineering, on Flickr Front panel off IMG_1665 by ultimate_engineering, on Flickr Sand blasted cross members inc repair to bumper and impact section due to rust IMG_1674 by ultimate_engineering, on Flickr IMG_1675 by ultimate_engineering, on Flickr Repair plate made for front offside out rigger near cab step IMG_1677 by ultimate_engineering, on Flickr The above panel will live here once this area has been repaired, blasted and painted. IMG_1670 by ultimate_engineering, on Flickr |
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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rowlesy
Vanorak murdered the murderwagen Joined: 09 Oct 05 Location: up unit! Status: Offline Points: 6466 |
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what happened to the b pillar? looks all kinds of wrong!
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UberFukz broke another! sucky sucky five dollah!
always out numbered never out gunned! RWS welding 07846 380 467 (worcs) |
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