syncro resto to conversion

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davidoft1
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Re: syncro resto to conversion

Post by davidoft1 »

fitting bfgoodrich hoses, original brake lines are perfect so thought easy ten minute job :)

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seems the fittings are to short so run out of thread before sealing :(

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new longer fitting for comparison, luckily I had some new spares :D

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that's better

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as I had to re- flare the pipe which would have left it to short I though I may as well make new 8)
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silverbullet
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Re: syncro resto to conversion

Post by silverbullet »

A rear disc conversion kit with full-length Aeroquip flexis would fix that ;)

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Cobra88
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Re: syncro resto to conversion

Post by Cobra88 »

Im just in the process of ordering a fitting kit from Ian :)
____________________________________________
84 CaravelleGL 1.9 DG WBX Bronze Beige Metallic auto

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irishkeet
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Re: syncro resto to conversion

Post by irishkeet »

looking great David :ok

davidoft1
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Re: syncro resto to conversion

Post by davidoft1 »

silverbullet wrote:A rear disc conversion kit with full-length Aeroquip flexis would fix that ;)

Sent from my S60 using Tapatalk

its to slow for that ;)

davidoft1
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Joined: 27 May 2009, 18:56
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Re: syncro resto to conversion

Post by davidoft1 »

irishkeet wrote:looking great David :ok


thanks :D

davidoft1
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Location: hayling island

Re: syncro resto to conversion

Post by davidoft1 »

as I had to run new brake lines to the front as the original was rotten but also syncro is slightly different at the rear and to the front caliper hoses , I decided I may as well go the whole hog and replace them all :o


back end finished

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new front caliper hard line, new holes drilled for hose bracket

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front brake lines going in along with clutch line

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rivnutting for caliper brackets, original is big self tapping screws but I have a riv nut gun fitttings and m6 bolts to hand

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davidoft1
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Re: syncro resto to conversion

Post by davidoft1 »

stripping out the wiring for the automatic inhibitor switch,
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shortened the starter wiring by around 3 feet :D

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soldered taped up and waterproof

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davidoft1
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Re: syncro resto to conversion

Post by davidoft1 »

so I think that most of the additional stuff done along with the fabrication side done, I wanted to do a satisfying bit 8)


diff lock vaccum loom

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diff lock electrical loom

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unravelled and checked for damaged pipe, terminal etc, luckily its all good :D

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Last edited by davidoft1 on 01 May 2020, 01:32, edited 1 time in total.

davidoft1
Posts: 982
Joined: 27 May 2009, 18:56
80-90 Mem No: 16628
Location: hayling island

Re: syncro resto to conversion

Post by davidoft1 »

I need to install the non return the inlet out let and vacuum accumulator

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this unequal T need to be in the brake vacuum hose

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cutting through the original main brake vacuum hose to insert the T

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A bit of boiling water to soften up the vacuum hose

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T Piece successfully installed without snapping the small pipe off :lol:

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needed to drill this out slightly to get the grommet and pipe through

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non return, accumulator and vacuum lines installed :D

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davidoft1
Posts: 982
Joined: 27 May 2009, 18:56
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Location: hayling island

Re: syncro resto to conversion

Post by davidoft1 »

difflock electrics going in, the difflock loom tucks nicely through the main loom grommet and follows the main loom to the back of the van

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davidoft1
Posts: 982
Joined: 27 May 2009, 18:56
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Re: syncro resto to conversion

Post by davidoft1 »

original zinc plating still intact, the gear rod protection does its job :)

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interesting find, im assuming someone added this to prevent the gear rod filling with water

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stripping gear rods for inspection, cleaning etc

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checking it fits in the cross member I modified

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lick of paint to protect them

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this old servo boot off a bay window servo fits the gear rod and front tube perfectly 8)

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all bits fitting together

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all bolted in place

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front gear rod bolted to the gearstick

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davidoft1
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Re: syncro resto to conversion

Post by davidoft1 »

stone chipping the fuel tank cavity and repairs I carried out

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safety first :D, this stuff is nasty

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all a bit wet but will look perfect once dried

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davidoft1
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Joined: 27 May 2009, 18:56
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Re: syncro resto to conversion

Post by davidoft1 »

bit of interesting fuel tank strap detail, so it seems they have bushes to allow the straps to move a little when bolted up, mine were missing so had to make a couple out of a bit of bell housing dowel I had laying about, perfect fit though :D

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and fitted

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davidoft1
Posts: 982
Joined: 27 May 2009, 18:56
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Location: hayling island

Re: syncro resto to conversion

Post by davidoft1 »

time to fit the fuel tank

new fuel lines breathers etc

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due to being unable to summon a human assistant I used the jack and a block of wood to tease the tank in, a bit tricky but not to bad

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filler pipe etc next

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