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Old 10-14-2012, 10:03 AM   #211
SpeedoJosh
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I'd kill for a Syncro Doka with a TDI. Literally kill
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Old 10-14-2012, 05:11 PM   #212
a1fa
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You can import one cheap... All it takes is granola, and time to follow through the maze of processes.
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Old 10-14-2012, 07:44 PM   #213
Hodakaguy OP
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Progress has been slow lately, been working a lot of overtime.

Today I assembled the brakes on the passenger side and re-installed the tire.

Parts cleaned up, new wheel cylinder....going back together.




Hard line and new Stainless brake hose installed.




My friend Mike torquing the rear axle nut to spec while I snap a pic :-)




Sitting on the wheel again....oh yeah!






Installed the drivers side trailing arm.




That's all for tonight :-)

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Old 10-14-2012, 07:59 PM   #214
SpeedoJosh
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I was about to ask what was the tank fill doing there, then remembered you're rocking a Syncro.

a1fa - Yea, I know importing is possible, but mucho expensive. Might be going to Germany though in a year, and if I do, you can bet I'm bringing back a Doka Syncro TDI.
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Old 10-14-2012, 09:25 PM   #215
Mr. Fisherman
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Do you think you will ever do anything like this with it?

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Old 10-15-2012, 06:29 AM   #216
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Quote:
Originally Posted by Mr. Fisherman View Post
Do you think you will ever do anything like this with it?


Ahhh....NO!

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Old 10-15-2012, 06:31 AM   #217
ducnut
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Quote:
Originally Posted by Hodakaguy View Post
Progress has been slow lately, been working a lot of overtime.
Nothing wrong with that, as overtime funds projects.
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Old 10-28-2012, 06:23 AM   #218
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Progress.

Installed the drivers side trailing arm.




It started to rain early in the am and the forecast didn't look like it was going to change all weekend so a improvised shelter was in order.




Brakes re-installed. To save time I had a few of the smaller driver side parts powder coated at a local shop while I was working. They powdered the mating surface area on the hub although I told them to leave that bare. I will strip it and re-powder it myself later, don't want a wheel loosening up if the powder wears etc.




Shock and spring installed.




Brake lines installed.




Wheel installed and axle nut torqued. Sitting on it's wheels again! :-)



Before...




After...




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Hodakaguy screwed with this post 10-28-2012 at 06:36 AM
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Old 10-28-2012, 06:56 AM   #219
zgfiredude
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Beautiful work, now, what's next? How's the motor coming?
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Old 10-28-2012, 07:16 AM   #220
Hughlysses
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It is truly beautiful work. One question:


The new coil springs look to be ~6 inches taller than the old ones. The trailing arm appears to only lightly loaded yet the top ~5 coils of the spring are almost fully compressed. Are you really going to get much more useable suspension travel out of this setup?
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Old 10-28-2012, 08:03 AM   #221
ducnut
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Quote:
Originally Posted by Hughlysses View Post
The new coil springs look to be ~6 inches taller than the old ones. The trailing arm appears to only lightly loaded yet the top ~5 coils of the spring are almost fully compressed. Are you really going to get much more useable suspension travel out of this setup?
That is a progressive-rate coil spring. It is wound to softly ride in the initial travel and, then, get progressively stiffer as the wraps contact one another and the spring compresses.
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Old 10-29-2012, 07:32 PM   #222
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Little progress after work tonight.

Starting to get the engine ready to bolt up to the trans. Installed the new plugs, wires and coil back on the engine.




Installed a Vanagon temp sender in the reverse cooling manifold next to the Subaru sensor.




Bolted up the alternator and AC compressor. Here I ran into a little problem, the stand off for the heat shield is interfering with the AC belt. I pulled the stand off and moved the belt to the other side but it's still rubbing on the standoff. Red Arrow.




I finally just removed the stand off, the heat shield is plenty sturdy so I don't think it will miss this one piece.






Hodakaguy
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Old 10-29-2012, 07:33 PM   #223
Hodakaguy OP
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Quote:
Originally Posted by zgfiredude View Post
Beautiful work, now, what's next? How's the motor coming?
Thanks, getting ready to install the engine/trans soon....Then move it inside the garage :-)

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Old 10-30-2012, 07:03 PM   #224
Keith
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Nice progress.
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Old 11-02-2012, 04:55 PM   #225
Hodakaguy OP
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Time to get the engine and trans mated up.

First off remove the Subaru flex plate on the Engine.




Ok....removed.




RMW Adapter plate in place.




Ok...time to get the flywheel ready to mount up. The RMW flywheel comes with the pilot bearing pre-installed. The RMW Roller bearing is a lot beefier than the OEM VW needle bearing.




Since it's a sealed bearing I decided to check it for grease before installing it on the engine. I learned a long time ago with sealed dirt bike wheel bearings that a lot of new sealed bearings are almost dry from the factory, it's a good idea to check/pack them with good grease before installation.




To my surprise the bearing was packed full of grease....Nice! I would have liked to flush the grease out and replace it with good quality Bell Ray grease but since the bearing is already installed and I can't easily access the rear seal I decided to just button it back up. Once your done just pop the seal back in place.




Flywheel installed on the engine.




Coating the clutch disk splines with a light coat of Honda Moly 60 Paste.




Sachs/Kennedy Stage 1 Clutch bolted in place.




Throw out bearing mounted up, input splines and cross shaft arms received a light coat of Honda Moly 60 Paste.




Engine and trans bolted together.




Made a slight bend in the EGR tube for more clearance between the tube and the radiator hose.




Installed a piece of fire braid on the EGR tube, should keep the heat from the tube away from the radiator hose.




More to come.

Hodakaguy
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