VW Syncro Westfalia - Build Log with Pics

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

  1. Xtremjeepn

    Xtremjeepn Motorhead!

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    Lookin sweet!:clap Good job !!
  2. a1fa

    a1fa Throttle Jockey™

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    Sexy craftman jacks!
  3. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Those jacks have held up great and are super handy!

    Hodakaguy
  4. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Time to start getting the brakes installed.

    I'll be installing a set of Front CV Protectors but thought I would mock up the brakes to make sure everything fits.

    I wanted to upgrade the front brakes on the bus since it's a heavy vehicle and the OEM brakes are marginal at best. I went with the VanCafe Big Brake kit which is a Audi based kit, You can save some money by piecing it together yourself but in the interest of time I just ordered the kit.

    Some Stainless Steel hoses to replace the worn out OEM rubber units, should provide a more solid pedal feel.

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    New stainless steel dust shields.

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    Kit came with 285mm vented rotors to replace the OEM 250mm solid units.

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    50% greater pad contact surface than the OEM pads.

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    Installed for mock up.

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    Everything fit up perfectly with proper clearances etc. The one thing I don't like about the kit is there is no tab to hold the hose/metal tubing to the caliper. Instead they provide you with a snap tie to keep the hose from flopping around......Hmmmm [​IMG]

    Well the snap tie just isn't going to cut it. The Audi calipers have a pre-tapped hold to accept a bracket but the VW bracket is the wrong angle. I did try swapping the VW brackets left to right and they do fit on the Audi calipers that way, but the brackets are to short and they stretch the brake hose at full extension.

    Stock bracket at red arrow below.

    [​IMG]


    I'll fabricate new brackets before going any further.

    More updates soon.

    Hodakaguy
  5. RickS

    RickS Been here awhile

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    Altus, OK
    Wow, nice build. I have never heard of a 4x4 bus. Learned something new today. Actually I do not thinking had ever seen one, but I will pay attention and look at one in person. Makes me want to work on the 57 Chevy
  6. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Ok here's my solution for a bracket to hold the brake line in place.

    Started with some 1" strips of stainless steel.

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    And mounted up. It holds the brake line nice and secure and allows enough slack in the hose for the suspension at full drop and a full left turn.

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    And mounted to the caliper. (Ignore the extra washers on the bolt holding the bracket onto the caliper, I didn't have the correct length bolt on hand to mock it up :-).

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    This picture is at full right turn with the suspension at full bottom travel. I had to mount the brake hose where I did to get clearance for the spring. I used a piece of rubber hose and a clamp to secure the hose. The clamp is spread apart and one side of the clamp mounted on each side of the bolt hole, if the clamp is mounted on the back side only there isn't enough clearance for the spring.

    [​IMG]


    Hodakaguy
  7. bobfab

    bobfab Long timer

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    you my friend are quite the artisan! Looks awesome!!

    Whats the target completion date for the project?
  8. madeouttaglass

    madeouttaglass The AntiHarley

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    The Lost Coast of California
    Well there goes many of my projects.:D

    How much higher will this end up being compared to stock?
    Is the previous owner local? I wonder what he/ she would think of this machine once it is finished.
  9. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Thanks, I'm shooting for May but we'll see. Lots of small items to go still.

    Hodakaguy
  10. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    It will be about 3" higher than stock with the lift and taller tires. Yeah the original owner is local, I'll be driving it over there for her to look at once completed :-)

    Hodakaguy
  11. ian408

    ian408 Oh? Administrator

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    Santa Clara, CA
    Impressed with your progress so far. Looks great!
  12. rider1150gsadv

    rider1150gsadv € Fl Keys Fishing Guide €

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    Simply awesome and the ONLY way to do a rebuild!
  13. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Time to get the seat installed again.

    Pulling out the old 3/8" cork material. A small leak in the rear heater had deteriorated them. Good time to replace it while its apart.

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    Laying down some Dynamat sound deadening material in the low spots before re-installing the new boards.

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    Got a good deal on some 3/8" finished oak plywood, here I'm replicating the old cork material.

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    That's better.

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    My friend Mike helping out, here he's removed the old propane tank. I'll be replacing it with the new unit that holds 10% more.

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    Had to do a little trim work to get the new tank to fit, it was off by 1/8". I think I'm going to undercoat the ends on the tank as well as the bottom gaurd/bracket to keep them from getting chipped up from rocks and rusting.

    [​IMG]


    More progress tomorrow.

    Hodakaguy
  14. kobudo28

    kobudo28 Banned

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    NICE!!!!!!!!!!!:clap
  15. jesusgatos

    jesusgatos fishing with dynamite

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    on the road
    Good work. I'd let you work on any of my projects.
  16. Robb Mc

    Robb Mc what?

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    San Francisco, CA
    Ooh. Where'd you find that propane tank? I'm looking for something similar.
  17. Robb Mc

    Robb Mc what?

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    Never mind.. I remembered gowesty and took a look there...
  18. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

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    Drinking from the Stanley Cup!
    Be careful with dissimilar materials on a fuel cell. Knowing you it will be well grounded but could tell you stories about unintended capacitive effects.g
  19. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    Wish we lived closer, would be fun to help out in designing parts, projects etc!

    Hodakaguy
  20. Hodakaguy

    Hodakaguy NorthWest Adventure Rider

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    The tank is steel so it shouldn't have any dissimilar metal issues :-)

    Hodakaguy