VW Syncro Westfalia - Build Log with Pics

Discussion in 'Shiny Things' started by Hodakaguy, Jun 25, 2012.

  1. oregoncoast

    oregoncoast Racing Like a Noob

    Joined:
    May 15, 2007
    Oddometer:
    4,543
    Location:
    Duh!
    Beautiful work...as always :thumb
  2. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,939
    Location:
    Drinking from the Stanley Cup!
    Wow Tom, that is looking good :lurk :thumb :thumb

    What are you preping the axles for?
  3. kobudo28

    kobudo28 Banned

    Joined:
    Sep 22, 2005
    Oddometer:
    5,888
    Location:
    New Hampster. Live, Freeze and Ride.
    :clap Good to see you back at it. I appreciate your craftsmanship and attention to detail.

    File this thread under..."How to do things the right way."
  4. ducnut

    ducnut Long timer

    Joined:
    Feb 9, 2009
    Oddometer:
    3,321
    Location:
    central IL
    I did the 4-light high beam conversion on my Silverado. My relay power runs straight off the battery, as it's right behind the left headlight. Where did you tap into? The main power to the panel?

    Very "euro". I like it.
  5. madeouttaglass

    madeouttaglass The AntiHarley

    Joined:
    Mar 7, 2009
    Oddometer:
    3,637
    Location:
    The Lost Coast of California
    Nicest. Syncro. Westy. Ever.
    There may be more radical ones, but this will be the best sorted. Damn.
  6. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    Going to powder coat the front axles the same color red that the back axles were done in :evil

    Hodakaguy
  7. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    The fuse box had a couple open slots on it's power distribution block so I was able to tap in at the fuse box :-)

    Hodakaguy
  8. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    Since I needed to take the lights out one more time to clean up the wiring I decided to add local grounds at the same time, this should guarantee no grounding issues with the lights.

    Soldering and heat shrinking the new ground wire to the harness.

    [​IMG]


    Wiring cleaned up and ground installed.

    [​IMG]

    [​IMG]


    Hodakaguy
  9. Mrmerlin

    Mrmerlin K1300S fast as shi..

    Joined:
    Oct 16, 2009
    Oddometer:
    341
    Location:
    Philly PA
    really like the headlight upgrade,
    I would put a piece of 3M paint protectant film on all of the glass,
    check out the possibility of using some HID lights for the low beams,
    they are reasonable priced and put out lots of light suggest to use 4300kv version for the best light not the 5600 its too blue
  10. Mr. Vintage

    Mr. Vintage Family Dude

    Joined:
    Jan 19, 2007
    Oddometer:
    867
    Location:
    The Palouse
    Lookin' good, Hodaka. What kind of 7" lights are those? I'm just curious what you went with; I have H4 copies on my van and I took a rock to one, so I'm looking for replacements. I think I'll get some of that clear headlight film too - it seems that with their carefully streamlined shape vanagons might be more susceptible to road debris.:D
  11. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    I'm using the bosch 1 305 603 038 assemblies. I've used the 3m headlight guard before, good stuff!
    Yeah the Vanagon is pretty streamlined lol.
    Hodakaguy
  12. ducnut

    ducnut Long timer

    Joined:
    Feb 9, 2009
    Oddometer:
    3,321
    Location:
    central IL
    If the housing is not a projector beam, a HID bulb will just scatter the light, which blinds every oncoming driver. A projector beam is a lot like pencil beam reflector in that it concentrates the beam onto a desired area. A standard housing isn't much more than a reflector or mirror behind a bulb. If you compare a standard type bulb to a HID bulb, you'll see they are totally different in the way they direct light.
  13. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    This is the same experience I've had with HID bulbs in Non-HID housings. I think the H4's in the grill and a couple HID's on the push bar should work pretty good.

    Hodakaguy
  14. a1fa

    a1fa Throttle Jockey™

    Joined:
    Nov 1, 2006
    Oddometer:
    13,906
    Location:
    Arkansas
    HID is not good on the Vanagon. It will blind oncoming traffic. I'm thinking about replacing my halogen fog lights with LED lights.
  15. slackmeyer

    slackmeyer Don't mean sheeit. .

    Joined:
    Jul 23, 2007
    Oddometer:
    3,181
    Location:
    Berzerkeley, CA
    The retrofit source has some nice HID projectors for a reasonable cost, to retrofit existing headlights, or mount them up as driving lights. I put one in my motorbike, really nice light and clean cutoff.
  16. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    A little powder coating today in preparation for getting the front end back together.

    Pre-heating the axles a bit in the oven before heading outside to powder coat.

    [​IMG]


    Hanging to cool down after coming out of the oven.

    [​IMG]


    Preparing the hubs to receive powder.

    [​IMG]


    Finished product.

    [​IMG]


    Hodakaguy
  17. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,939
    Location:
    Drinking from the Stanley Cup!
    Purdy :1drink
  18. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    Progress continuing.

    Time to get the hubs put back together.

    Pressing the new bearing into the housing.


    [​IMG]


    Good thing I saved the old bearing. The old bearing outer race worked great to finish seating the new bearing.

    [​IMG]


    Installing the new Circlip

    [​IMG]


    The old bearing race is also a perfect fit to drive in the new seals.

    [​IMG]


    Pressing the hub into the new bearing. The bearing inner race is being supported from the bottom.

    [​IMG]

    [​IMG]


    Lookin good.

    [​IMG]


    Finished applying a coat of POR 15 to all the newly drilled screw holes for the center lights, sealed all the connections with Dielectric grease and re-assembled/tested the lights.

    [​IMG]


    Hodakaguy
  19. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
    Jul 30, 2007
    Oddometer:
    2,113
    Location:
    Eastern WA State
    Installed the new Rocky Mountain Westy plate bumper today.

    Original bumper removed.

    [​IMG]


    And the new RMW Plate bumper installed :-). Oh yeah, that looks a LOT better.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    Hodakaguy
  20. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,939
    Location:
    Drinking from the Stanley Cup!
    Dig that :thumb :thumb