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Topic ClosedLimey the Syncro 16 2.5TDi Westy. 330mm Brakes!!

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Baxter View Drop Down
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Scruff Daddy

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Direct Link To This Post Posted: 07 Oct 07 at 22:33
I have a trial repair section at the machine shop, for replacing the ends when they drop off, maybe what you need?!
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Direct Link To This Post Posted: 09 Oct 07 at 10:23

Interesting link

Go Westy Plastic pipe adapters

http://www.gowesty.com/library_article.php?id=113

1990 1.9td SYNCRO DOKA
1988 1.6td SYNCRO AMBULANCE
1989 2.1i LPG Camper
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Direct Link To This Post Posted: 09 Oct 07 at 23:18

Thanks guys.

I think I'll use the stock syncro pipes and then the factory extension rubber hoses etc.

Interesting link re-Go-westy stuff. Not sure how they're supposed to stop the end of the pipe dropping off as the pipe usually disconnects right under the clip...

MG

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Direct Link To This Post Posted: 13 Oct 07 at 08:03

Ok now that the Bluestar has gone, all my work is being focussed on the 16.


Again looking at the front to rear plastic coolant pipes, the main pipes in the engine bay are much bigger in diameter than the joining sections which VW use on the syncro diesel so back to the Diesel 2WD pipes!





Here is a pic of where the coolant pipes enter the Bluestar 2WD Diesel engine bay and are held in place with factory clip.


By moving them back an inch or so, I was able to get them to sit fairly comfortably next to each other and up against the tank but not under any pressure. They're not fitting up into the bodywork because of the interference of the tank but then looking at the way the rubber hoses sit coming off the engine, they didn't really want to fit there anyway. It hit me, the engine is sat lower than in a SA van... doah! ok so they're all connected up and fairly happy. I'll weld in a section from another van so that the pipes can be held in position rather than floating about. Up front, one of the rubber hoses was now too short so I replaced that with a new section of pipe and again used factory spring style clips. These are now used throughout the cooling system. Wow... the cooling system's all connected up!


Next section is the wiring... I've been dreading this but hey it needs to be done.





After an hour of struggling to get a smaller grommit over the main loom so that it fits nicely when going into the engine bay, and another hour of carefully threading all the plugs of the loom etc through a 38mm hole... the loom is in the engine bay and I've start connected things up. There are a few spare plugs on the loom so I'll have one for the aux water pump which I'll connect up to either an output from the ECU or a temp switch I'll fit later on. I will have to cut the original wires going to the airflow meter and then splice that section in further up the loom close to the ECU as the airflow meter now sits outside of the engine bay.







Using rivnuts again, the Audi electrical plugs are bolted to the engine bay wall and the loom sits nicely running along the back wall.





The wood is there to protect the tank which is directly behind where I'm drilling holes!







I've bought a set of hole saws, these are great! so the final hole has been cut for the snorkel/inlet pipe to go through. I'll be adding another 90o section outside aswell and then welding the whole of that s-bend section to the body so it's a permanent feature along with a mushroom snorkel on top outside.











http://www.innovation4x4.co.uk/snorkels.htm


MG



Edited by Ghia - 15 Nov 09 at 15:06
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Direct Link To This Post Posted: 13 Oct 07 at 08:19
Can't wait!

Very interested in the snorkel.
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Direct Link To This Post Posted: 13 Oct 07 at 14:44

Small update while I drink my cup of tea!


Finished with the wiring in the engine bay and fixed up all the small ancilleries, vacuum reservoir, boost pressure sensor, vacuum line solenoid etc etc... there's not a lot of room for anymore!







Engine bay staring to get tidier if that's a word. Charge cooler head tank mounted to the inlet manifold and the pump will be directly below for easy pipe routing.


MG



Edited by Ghia - 15 Nov 09 at 15:07
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Direct Link To This Post Posted: 13 Oct 07 at 15:28
Looking good Mike - inspired me to go off to the agarage and fettle the Scooby engine.
T3 Westy, T3 Syncro (the ScoobyVelle), New Beetle Cab, 2 x Polos - I have too many projects
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Direct Link To This Post Posted: 13 Oct 07 at 22:52

Hope that engine is nice and clean

The little bits and pieces on a project really take up time!

After another days work, I've almost finished off the wiring in the engine bay, connected the airflow meter wiring up next to the ECU with solder and heat shrink. I removed the old accelerator cable, mechanism up front in readiness for the Golf Throttle pedal assembly. There's no room on a RHD van for it but there's a big space above the throttle pedal on a LHD. We'll see when I get one!

The list of things to do is large!

Tig up the charge cooler and clean out thoroughly

Tig fittings onto it so it's bolted down to the body,

Tig new water pipes to it so they face in the right direction,

Make a new bracket for the Charge cooler water pump so it doesn't sit so close to the exhaust

Heat wrap exhaust and tighten to turbo fully (allen nuts)

Check routing of all vacuum pipes etc

Buy lots of 1/2" pipe for the charge cooler system and plum it in,

Replace the plugs on the wiring for the pump and the loom as they're not water resistant,

Have all boost pipes bead rolled so they hold pressure,

Add (tig) necesary take off pipes to boost and inlet pipes for breather system pipes

Fit wiring plug to spare wires in loom for aux cooling system pump, trace up in main loom and research if ECU has function to switch it on, if not fit temp sensor and wire up.

Fit front to rear wires for the throttle potentiometer, immobiliser, speed sensor, clutch/brake pedal switches.

Fit oil cooler system with radiator up front

Finish wiring off with feed to the Audi loom and integrate that into the VW loom

Connect up rev counter wiring and adjust

Fit power steering bracket, tank, rack and pipes (not necessary for MOT)

Make bracket for aux water pump

Fit fuel return line from filter to tank

Fit fuel lines in engine bay from and to filter from the diesel pump

Fit coolant system cap and mount coolant tank bracket so it fits under the lid

Fit remaining bolts to the bell housing and torque up

Seal bell housing to engine and fit breather pipe

Reconnect gearbox breather pipe and check all bolts for tightness

Fit prop shaft and protection bars

Make engine/gearbox protection bars to incorporate rear engine mounting support

Weld snorkel pipe work to body and finish snorkel

Fit new plastic vent and cut to go over snorkel

Fit clips to all boost/inlet pipes

Fit gauges to cab (boost, oil temp, gearbox oil temp)

Build 4.57 gearbox (with mods) and fit 4.57 front diff

Will add more when I think of it. That should keep me going for a week minimum!

MG

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Direct Link To This Post Posted: 15 Oct 07 at 19:18

When chatting to a friend earlier this evening, he was asking how much I'd spent so far on the engine conversion... I did a very quick calculation in my head and decided that I could have done a Subaru Turbo conversion using all the Small car parts for less money! These things aren't cheap!


Ah well, I've got this far etc etc and it should be great offroad.


Todays update is fairly small one but another step closer...





My latest bit of kit is this lamp which is fantastic and comes well recomended from both Baxter and myself!





And just a small pic of how the van is looking at the moment on wheels which really need painting!





MG



Edited by Ghia - 15 Nov 09 at 15:08
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Direct Link To This Post Posted: 15 Oct 07 at 21:45
what a beast!  looking really good!
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Direct Link To This Post Posted: 15 Oct 07 at 23:16


Thanks Shapey. It seems to be taking a very long time even for me!


After buying silicone hoses, stainless steel/aluminium pipes and bends from all over the country, I find a place less than 3 miles away from me which could have supplied everything with ease! Ah well now I know for future projects.


http://www.venairsport.co.uk/


I bought this earlier from ebay... a bargain and just what I need for the 16. Innovation didn't seem that bothered about selling anything!




MG



Edited by Ghia - 19 Dec 09 at 11:12
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Direct Link To This Post Posted: 16 Oct 07 at 07:00
Wow mike - beginning to look the business- had to do a double take on the van shot until I realised that it was on axle stands!!

Thought you had gone uber tall.


PS: Got the ScoobyVelle back from the bodyshop - you will be seeing it later!
T3 Westy, T3 Syncro (the ScoobyVelle), New Beetle Cab, 2 x Polos - I have too many projects
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Direct Link To This Post Posted: 16 Oct 07 at 11:26
What size are those wheels and tyres Mike? They look massive
Alan Hayes - Campervan Culture
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Direct Link To This Post Posted: 22 Oct 07 at 16:40
won't get many clothes in the wardrobe when it's built eh ?
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Direct Link To This Post Posted: 23 Oct 07 at 22:25

Aidan, Nah the wardrobe will be unaffected by the wiring etc, it's just the rear cupboard which will take a hit space wise. You'll be telling me I need to add a hightop to it next!

Vlux, I'm running 7.50X16's. They're fairly big . I have another set of 16 wheels with 245/75/16s for street use.

MG

 

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Direct Link To This Post Posted: 25 Oct 07 at 23:04

Originally posted by Beaker Beaker wrote:

won't get many clothes in the wardrobe when it's built eh ?

Wot, no space for clothes?!!  Right, I'm off!!!! 

I may be his Wench, but hey, I chose to be!
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Direct Link To This Post Posted: 21 Nov 07 at 10:58

I can see me designing an extending wardrobe for you


 


Not much going on with this atm due to the Tristar work.


The wheels (another ebay bargain) will be going on with 245/75/16 tyres once I have the Tristar wheels.


http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1& ; ;item=190166085868&ssPageName=STRK:MEWA:IT&ih=009



Got the inlet pipe finished, just need to add the mushroom top.





MG



Edited by Ghia - 19 Dec 09 at 11:14
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Direct Link To This Post Posted: 24 Nov 07 at 11:34

Wow, Inspired! That's a serious project, respect!

Motexion, not cheap plywood!
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Direct Link To This Post Posted: 25 Nov 07 at 22:26

its comeing on well now , how long till shes up and running ?

also did you have 2 vac pipes on the old audi air box ?

what was the engine out ov ? engine code ?



Edited by BUS.BOY
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Direct Link To This Post Posted: 25 Nov 07 at 22:57

Clap

I'm curious, whats the plan for covering the rear vent with the snorkel pipe in the way.

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