PetenAli's List of jobs to be done on our Syncro

[jebiga41]

Oops forgot a few things like front window seals yet to be fitted and windscreen seal it never ends

[PetenAli]

Thanks jebiga41. There's a consistent picture emerging of the type of work that needs doing to Syncros - although I guess it would be the same for most 25 year old vehicles.

I was interested to see the third brake light and additional reversing light in your list. How are you going to do the brake light? Stick one in the top of the rear window or drill the tailgate before you paint it?! I could do with an extra reversing light as well.

Its also reminded me that I need to add to my list a non working rear screen heater and rear washer (just discovered that a bundle of wires going through the tailgate grommet have been snipped - presumeably during the full resto...)

Heater blower etc just arrived from Brickwerks. Not bad since I ordered it at about midday on Friday. Thanks again guys.

[jebiga41]

You just reminded me of more jobs I need to do here's a photo of the rear
sorry not great but if you zoom in you'll see where the third brake light is recessed into the westy locker shelf also extra reversing light (jcb or tractor work lamps do the job) is on the roof just above the waffle boards but could be mounted in beside the rear lights which works well

[SyncroSwede]

On my old Syncro I put a twin 55w work lamp from an agricultural supplier on the bumper top so I didn't have to drill the body itself. It was wired to a relay in the engine space with a three position switch on the dash. On, off and the third was spliced into the reverse light switch so it came on automatically when reverse was selected. Made reversing so much more relaxing!

[PetenAli]

On my old Syncro I put a twin 55w work lamp from an agricultural supplier on the bumper top so I didn't have to drill the body itself. It was wired to a relay in the engine space with a three position switch on the dash. On, off and the third was spliced into the reverse light switch so it came on automatically when reverse was selected. Made reversing so much more relaxing!

Thanks SyncroSwede. A 55w work lamp seems to be the way to go. The three way switch is good idea as well.

[syncropaddy]

This is how I did a high level brake light ....... two LED red side markers on the overhead storage thing



And my reversing light is a Hella worklight

[PetenAli]

This is the latest list - its grown!!

Just picked up the Syncro from Futbus. Dave has got everything sorted on the 4WD side and did a couple of other bits (like a dropped door) just because they were getting on his wick! What a top bloke!! For a Syncro getting the VC, lockers and decoupler sorted is fundamental. Even the flashing light works on the front diff lock and before Jim put his post up I didn't even know this feature existed.

Not long after we bought our Syncro we met up with Al v-lux. As well as introducing us to the pleasures of off roading in a Syncro he made lots of useful suggestions that we've started to follow up as time and money allow. He also said that it would probably be about 2 years before we got ours just how we want it. Experience so far suggests that it will be nearer 3 or 4 years!

I sat down the other evening and made a list of jobs that need doing sooner or later. I also followed Lloydie's thread on his Westie and what he said about using a thread as motivation to keep going. Going to the Picos last month with a group of very experienced Syncronauts was also incredibly useful. I thought this list might be useful to anyone planning on buying a Syncro - just to give an idea of what you are letting yourself in for - so here goes with it:

Mechanical
Sort VC (failed open) and recent loss of difflocks and decoupler - the van is currently at Futbus getting this sorted. DONE
Change brake fluid (could be fun as the bleed nipples don't look like they've been opened for a long time)
Check / refurb / renew CV joints
Replace springs and sort out shocks
New bushes on front suspension
Usual maintenance on engine + compression test

Electrical
Sort out the rats' nest that is the wiring around the leisure battery (lots of people have played with this over the years I think)
Fit second 12v socket
Fit new ICE headunit
Fit CB (and sort out ariel)
Remake earth on n/s front indicator
Fit KC Daylighters spots and fogs (ebay purchase with complete looms)
Replace knackered heater blower (new one on the way from Brickwerks)
Fit individual relays to headlights (as per Wiki) and rewire
Wiring for oil pressure and oil temp guages (see below)
Sort non working heated rear screen and rear washer.
Sort non working horn and replace it with something that sounds less wussy


Body
Fit wheel arch liners DONE
Fit new roof canvas DONE
Underseal rest of underneath
Waxoyl doors, tailgate, cavities etc
Sort out why windscreen wash reservoir leaks when its filled up
Wash and polish

Interior
Make new battery covers (to replace black painted plywood monstrosities currently in place)
Tidy kickboard of rear seat
Fit CO and smoke detectors
Get fridge running on gas
Buy and fit Propex
Sort / renew 240v system which is 25 years old

In addition to that lot I've decided to stick with the 2.1 DJ rather than look at an alternative. The one thats in at present seems to be OK but the trouble is that I don't know anything about its history and for some reason the engine number has been ground off which is a bit suspicious. I can also see that the head for cylinders 3&4 has been off as its much cleaner than the other one. Oil consumption is about .5 litre every 3k miles which isn't too bad. The plan is to build another 2.1 DJ to original VW spec or better. I've started collecting the bits (thanks again to Dave at Futbus) and have had some helpful info from Syncrosimon - thats why wiring is going in for oil pressure and temp guages. I've also been looking at Tencentlife's various threads and posts on the Samba. But that'll be the start of another thread.

We want to do as much of this as we can ourselves but I also know my limitations and want the key things to be spot on (which is why the bus is at Futbus at the moment). We have already had loads of help from people on here and hope that we can both provide some useful info as well as getting hints and tips from other forum users. First question is: "What did other Syncronauts have to do to their vans when they first got them?" - because I'm sure that there are things missing off our list...

Thanks in advance,

PetenAli

I've also come home with the makings of a sound 2.1 DJ which may not be a full on Tencentlife rebuild but hopefully will be close, reliable and long lived. I'm going to balance everything to within an inch of its life - but that's another thread!!

Next jobs are to fit the very neat CO detector supplied courtesy of Lloydy (it is the size of a packet of fags) and then the heater blower and associated bits - not looking forward to the second of these!!

[lloydy]

I've had the blower sitting in my garage for a few months now, not looking forward to it either..

[PetenAli]

This is how I did a high level brake light ....... two LED red side markers on the overhead storage thing



And my reversing light is a Hella worklight

Thanks Syncropaddy - I can see the way to go on both of these.

[PetenAli]

Finally got a few hours in the garage and started to strip down the 2.1 DJ from Dave at Futbus which I hope will be the basis of our new, fully rebuilt and a bit more powerful engine.

Got all the anciiliaries off except for the thermostat housing where the Allen bolts were so rusty that I couldn't get a key in them and the heads just crumbled when I eventually resorted to the trusty vise grips. Will have to work that one out!

Got a massive box of bits to clean already!!

Took the rockers off as well. They are seriously worn and will need a full replacement - following Tencentlife spec I am looking at 1:1.25s with swivel feet adjusters anyway so thats not too much of a worry. Also got to work out what cam to go for.

Big concern was that when I took the oil filler tube off a lot of very emulsified oil drained out. I'm hoping that this doesn't mean that the crank is going to be damaged beyond repair. I've got good con rods, bearings etc from Dave but a new crank would make a big hole in the budget.

Next step is to get the heads off and then pistons and liners before splitting the case. Big drag is that I'm about to catch the sleeper to London where I'm working for the next week - hence no time in the garage Still, got to earn the money for the bits!!

[KINGPRAWN]

Brave man Pete.... Financially that is!!!

[torchy]

First question is: "What did other Syncronauts have to do to their vans when they first got them?"

From 'new'...
replace engine replace both gearboxes

Sooner after...
replace engine again......
Still to do ...
I daren't look at the list in its entirety, but it includes
Engine rebuild
starter refurb/replacement
replace all window seals
new dampers and springs
interior, interior and interior.

Good luck Pete!

Hay Patrick I think you might need to find a better "engine provider" or do you have a spare in the front?

Now that would be interesting 4WD or is that a 2WD * 2 ?

[syncropatrick]

Heh, heh, heh, Torchy. The current 2nd hand engine is doing very well and I have no issues with it per se, but I am nervous after previous experiences so would like to swap in a good known rebuild. Pete OP seems to have the right idea and is rebuilding one early on to stick in, which is preventative maintenance for engines I have yet to learn.

[PetenAli]

All been quiet on the Syncro front lately - the joys of being self employed and having to take the work when its there - although the thought of going back to working for a large organisation like a local authority fills me with horror.

Anyway got out there today and got the horn fixed - ended up that both the dual horns were knackered and so I fitted a Ring replacement which I could get up out of the way of mud etc. Its got quite a good sound.

The old Futbus engine is in the garage now and slowly getting stripped down. Currently the thermostat housing is being a pain as the heads of the two Allen bolts that hold it on are rotten and I can't turn them. Can't really use heat as its a plastic housing. Will keep chipping away at it though. Had some really helpful PM conversations with Silverbullet about the engine and the planned spec for it is slowly coming together. When I have it fully stripped down I will know exactly what needs relacing and will start another thread. Ultimately I would like to go down the Megasquirt route but that is going to cost as I will need to pay someone to fit it as well - been researching it on the net and its way too complex for a digital immigrant like me!

Next big job will be the heater blower and when the dash is off I will fit another 12v socket, a map light, a new stereo, wiring for three guages and do the Wiki headlight upgrade (bought the cable and relays for this the other day).

Also been looking at LED strips to replicate Syncrosimon's indicator repeaters on the mirrors, for a third brake light and to give us some lighting in the very back when we open the tailgate at night - can't see a thing at the moment.

[jed the spread]

I had a go at my list today too and think I have finally gone through it and sorted the bits and bobs.

Connect the light bar back up,
Sort the flickering light on the diff lock dash board,
Finished off fitting the new alarm with pager to tell me it has been set off and what has set it off on the vehicle ,
Fitted a rear view camera,
Sorted the seat rattle,
Lined up my windscreen wipers properly,
Fitted a panel to hide my engines ECU etc out of harms way,
Stuck down the padded dash top properly,
Washed the van roof and looked at my engine for a while.

Hi five

jed