VW Syncro Westfalia - Build Log with Pics

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

  1. NoLurkerAnymore

    NoLurkerAnymore Adventurer

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    Jan 7, 2013
    Oddometer:
    10
    And it still gets better and nicer...
  2. ducnut

    ducnut Long timer

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    central IL
    That's the nicest, closest fitting, and most appropriate looking aftermarket bumper I've seen put on anything.
  3. PaulGinAZ

    PaulGinAZ FNG

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    Jul 28, 2007
    Oddometer:
    273
    Location:
    Chandler, Arizona
    Very nice work! I am a big fan of the Rocky Mountain Westy bumper setup. :clap
  4. RocketJohn

    RocketJohn Hook em' Horns!

    Joined:
    Apr 15, 2002
    Oddometer:
    11,492
    Location:
    Denver Metro
    Fantastic build! Thank you for sharing... Can't wait to see some video of this machine off the pavement! :clap
  5. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Oddometer:
    2,222
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    Eastern WA State
    Thanks for the comments....can't wait to see this baby finished myself :D

    Hodakaguy
  6. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
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    Oddometer:
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    Pressed the lower ball joints in this am. I removed the boots to press the joints and noticed there was very little grease in the joint from the factory.

    Here's a picture of the factory grease. The other ball joint had more grease that this one...but still not a lot. They are both Meyle joints, one had while lithium grease and one had a red grease in it.

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    I carefully cleaned all the factory grease out of the joints and re-greased them with Redline CV2 grease, working it down into the joint. They should last a LOT longer properly greased.

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    Inner seal pressed in to place. I had this part powder coated at a local company to save time. They did a good job other than coating a couple areas they shouldn't have and leaving a couple spots bare.

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    A coat of POR15 applied to the bare area around the inner seal.

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    Steering rack bushings removed.

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    The new PowerFlex Urethane steering rack bushing next the OEM rubber bushing that was removed.

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    After pulling the rubber boots off the steering rack you need to pry up the lock tab to separate the Tie Rod Assy from the steering rack.

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    My father giving me a hand cleaning up the steering rack :-) It is now a lot cleaner, although it has some undercoating on it that doesn't want to come off :-)

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    After seeing the factory grease in the lower ball joints I decided to check the new tie rod ends as well. They had more grease than the lower joints did although I fully cleaned them out and packed them with the same Redline CV2 grease as well.

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    The new steering rack rubber boots didn't come with clamps, a quick trip to NAPA turned up the correct OEM style Oetiker clamps :-)

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    New boot clamped in place.

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    Nice thick coat of BelRay grease installed on the steering rack bushings...ready to install.

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    Steering rack ready to re-install.

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    Using a Dremel tool and wire wheel to remove the powder coating from the tapered ball joint holes that the powder coating facility didn't cover.

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    Hodakaguy
  7. oregoncoast

    oregoncoast Racing Like a Noob

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    May 15, 2007
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    4,586
    Location:
    Duh!
    I saw a white westfalia in Tillamook this weekend, with the same headlight conversion, custom bumpers and washington plates, thought it might be you...guess not.
  8. klp

    klp Been here awhile

    Joined:
    Nov 29, 2009
    Oddometer:
    367
    Location:
    Andover, Ma
    I don't think I am in a minority here - when I see stuff like this it just makes me feel all warm and fuzzy... :D


    Great build and thread, I have really enjoyed watching this come together.
  9. a1fa

    a1fa Throttle Jockey™

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    14,784
    Location:
    Arkansas
    Hoodka, are you using stock EFI for the Subaru?
  10. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Yep...using the stock Subaru ECU/EFI. I had a friend running a LINK ECU on his H6, it never was set perfectly and as a result never ran quite right. I figured the factory spend a lot of time on the ECU mapping so I'd just use theirs :D.

    Hodakaguy
  11. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

    Joined:
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    Location:
    Eastern WA State
    Installed the Lower Control Arm bushings.

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    Power steering rack installed, lower control arms installed with Powerflex radius rod bushings.

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    Burley upper control arm installed.

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    Here's the factory grease in the upper ball joint....pathetic.

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    Cleaned out the old grease and packed it with Redline CV2 grease. Ready for service.

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    Now it's starting to look like something. Drive shaft freshly packed with grease and bolted in place.

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    Trying the Fox shock on for size. Looks like plenty of clearance....we'll see how it looks when the spring is in place.

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    More to come......

    Hodakaguy
  12. jesusgatos

    jesusgatos fishing with dynamite

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    on the road
    What wheels are you planning on running on this thing? Just picked up an old audi wagon with the same lug pattern and have been looking to see what's out there. Wanna run something small (15-16"), with big meaty sidewalls.
  13. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Location:
    Eastern WA State
    I'm running these 16" Mercedes wheels.

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    Here's a thread that has a whole list of wheels that fit the Vanagon: http://www.thesamba.com/vw/forum/viewtopic.php?t=203519

    Post pics up of your off road wagon when ya get it done :deal


    Hodakaguy
  14. ducnut

    ducnut Long timer

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    Those just look "right". :thumb
  15. dlearl476

    dlearl476 Two-bit Throttle Bum

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    Between Here and There
    Well, HG, I gave up on ever being able to afford your syncro once you get it done about 15 pages ago. :lol3

    But I may have found a nice Eurovan Winnie out west. :thumb
  16. jesusgatos

    jesusgatos fishing with dynamite

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    on the road
    Those wheels look great and thanks for the link. Was actually just skimming through that thread yesterday (took quite a while).
  17. Xtremjeepn

    Xtremjeepn Motorhead!

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    May 31, 2008
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    Location:
    SaddleRock, Colorado
    Sweet Syncro build. I've been looking for awhile but have just not found the right deal yet.:1drink





    ......which is why I picked up my Eurovan project:lol3

    http://advrider.com/forums/showthread.php?t=859597
  18. allonsye

    allonsye ("lets go!")

    Joined:
    Jul 9, 2006
    Oddometer:
    904
    Location:
    Harrisonburg, VA
    Seen last Sunday in Pulaski, VA on Rt 11 scores and scores of VW Vans, in neat rows and by color and year. One of the strangest sights I've ever seen. Who'd a thunk? Hoarding VW Vans:huh

    Love your build, I've a friend who built his nearly identical to yours. A van that drives like a sports-car. Quite the beast.

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  19. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    I've seen that in other threads....Kinda strange for sure.

    Hodakaguy
  20. mark883

    mark883 and the mysterians

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    Location:
    Buckeyeland
    Do you think maybe those are euro spec vans, maybe tied up for some reason due to EPA or USDOT standards? The headlights look euro, and the front plate holder looks kinda wide for the US. (I'm not a VW guy, maybe those headlights were US too. I could be completely wrong.)

    Maybe he's holding out for that 25 year exemption, then gonna flood the market with bug-vans? Or maybe is the secret FEMA holding area for illegal immigrant vans.