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Old 09-17-2012, 09:05 PM   #136
Hodakaguy OP
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Been working a lot lately so I haven't had a chance to work on the bus much. Did manage to get a little work done today though. Installed the new input and shift shaft seals. Now on to the starter.

I decided to install a Diesel TDI starter so I will have a reliable modern starter that will crank the 2.5L over without a problem, as a side benefit this starter is self supporting so you don't need to use the support bushing in the bell housing that is prone to wear.

I ordered a Bosch SR0408X starter and a Westy Ventures adapter plate, now to install them.

Starter and adapter plate.




Since I'm installing the setup in a Syncro the Diff Locker brackets need to be trimmed. I trimmed the brackets (at the red arrows) so they will clear the starter and powder coated them black.




With the adapter plate temporarily in place the starter is test fitted. You need to trim a small notch in the starter so the upper mounting plate nut has room to seat. (at red arrow)




Starter notched....




Installing the Diff lock brackets, here you can see why the notching is needed for clearance.




Another angle. Here the starter is bolted up tight, I applied a thin layer of Ultra Grey gasket maker to the mating surfaces to keep water out.




You need to notch the corner of the diff actuator to clear the edge of the starter.




Assembled, it's a tight fit but it all goes together.




Shift assy installed along with new rubber shift boots.




More to come

Hodakaguy
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Old 09-17-2012, 09:23 PM   #137
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Old 09-18-2012, 08:31 AM   #138
Rodzilla
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this is pretty darn cool to see come together!


This summer I was pulling my camper over Kenosha Pass and could see a VW van a few turns ahead. Naturally my first thought was dang...there isn't a passing zone for miles! I never caught up to him! I figure he must have a similar set up to what you are doing, because at 10k ft and 5% grades VW Vans just don't DO that around here!
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Old 09-19-2012, 07:01 AM   #139
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Met a guy last week driving a Synchro with a Passat diesel installed. He came from New York and told me he was just in from the desert the night before. No pictures, didn't want to appear weird.
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Old 09-19-2012, 06:58 PM   #140
kobudo28
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Hodakaguy, you are a craftsman!
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Old 09-20-2012, 09:46 PM   #141
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Please don't stop posting! I am addicted!
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Old 09-22-2012, 07:56 PM   #142
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Quote:
Originally Posted by Rodzilla View Post
this is pretty darn cool to see come together!


This summer I was pulling my camper over Kenosha Pass and could see a VW van a few turns ahead. Naturally my first thought was dang...there isn't a passing zone for miles! I never caught up to him! I figure he must have a similar set up to what you are doing, because at 10k ft and 5% grades VW Vans just don't DO that around here!
Yep, the extra power will be nice!

Hodakaguy
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Old 09-22-2012, 07:57 PM   #143
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Quote:
Originally Posted by SR1 View Post
Please don't stop posting! I am addicted!
Been crazy busy at work, I'll keep the updates coming as I get a chance to work on it

Hodakaguy
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Old 09-22-2012, 07:58 PM   #144
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Today's progress.

Pulled the cross shaft bushing.




Using dry ice and denatured alcohol to shrink the new cross shaft bushing for install.




New bushing in place.




The new cross shaft was the same as the old one, welded good on one side and the other side was almost not welded at all, very little penetration. I've read and been warned where the arms are prone to break off since they are really only welded on one side. Since I will be running a higher than stock pressure plate this will need attention.

Here's the side that's welded from the factory.




And the other side....






Now to take care of this problem before installing the new cross shaft. I placed a clamp on the outer edges of the arms before welding. I welded the outside first so the arms would want to pull towards the clamp, then across and to the inside edge. I measured the gap between the arms with a dial caliper before welding and after..no change :-)






Cross shaft with new bushing kit, ready to be installed. For a long time the bushing kit and seals were non existent, you can now get a new set through VanCafe. :-)




Cross shaft installed.




New clutch slave cylinder bolted up with fresh hardware.








New bearings going in the dry ice solution to be installed in the drivers side carrier.








Hodakaguy
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Old 09-22-2012, 08:10 PM   #145
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serious amount of patience.
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Old 09-23-2012, 08:39 AM   #146
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Good call on those welds. I have inspected many welds when I worked on oil-rigs in the North Sea and those welds were right up there in the crap department. They were pathetic to even sell the cross shaft that way. Great build!!
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Old 09-24-2012, 12:56 PM   #147
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meticulous doesnt begin to describe this thread.
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Old 09-24-2012, 01:32 PM   #148
Sniper X
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Again, awesome build thread! BTW have you seen that doc called "The Bus Movie"? It is great and they speak fondly about the Synchro.
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Old 09-24-2012, 08:48 PM   #149
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Quote:
Originally Posted by Sniper X View Post
Again, awesome build thread! BTW have you seen that doc called "The Bus Movie"? It is great and they speak fondly about the Synchro.
Thanks for all the comments, It's tough to stay focused some times since the end is so far away.

I haven't seen The Bus Movie yet but I've heard it's pretty good! Should be a fun watch

Hodakaguy
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Old 09-24-2012, 08:49 PM   #150
Hodakaguy OP
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Small amount of progress after work tonight.

Removed the rear bumper and tail lights in preparation for undercoating. This bumper won't be going back on the bus :-)






Removed all the "bolt on" items in the engine bay. Lot's of cleaning and sanding now :-(






Started on sanding....Lots of prep work to go still. There are a few areas that I will spot treat with POR15 before shooting the undercoating. Can't wait to get the undercoating applied....that will be the turning point and things can start going back together again :-)




Drilled out the froze cotter key on the drivers side axle, now I can finish putting the carrier together.






More to come.

Hodakaguy
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Riding Through History - NV RR: CLICK HERE
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