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

[PetenAli]

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.


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

[lloydy]

The names lloydy not lloydie unless you mean someone else?
Thing is you seem to have to spend a certain amount on getting everything working right. Then you start seeing other peoples vans, then the real spending starts
My next installment (will have to restart my build thread)
Charge cooler for the AAZ
Gearbox to Aiden for rebuild and longer gears
Proper renovation by metalmickey
TDI conversion
The cost of that list is probably the same as the price of a good 2WD westy, definitely a labour of love

[PetenAli]

lloydy

Major apologies for getting your name wrong. I meant you because you said about how much your thread helped you to keep motivated. You have been quite an inspiration for how you kept going over last winter so thanks for replying. You've also reminded me that once I've got my engine built I need to to get the gearbox and front diff to Aiden. Something else to add to the list

[lloydy]

Aw, shucks an inspiration! Never been called that before.
If your changing the brake fluid, I wouldn't bother trying to undo the bleed nipples, especially the rear. Just fit new wheel brake cylinders with new nipples. Might as well fit new flexi's as well .
If you've got power steering, maybe check the pipes, mine were rotten

[syncropaddy]

Just fit new wheel brake cylinders with new nipples. Might as well fit new flexi's as well .
If you've got power steering, maybe check the pipes, mine were rotten

Have to say lloydy .... you listen!

[lloydy]

Think I saved myself a lot of stress by changing the cylinders, especially when they are only £20 ish.
Sharing the love man...
And contrary to what the wife says, I do listen, it does sink in and I'm not just sitting there nodding

[Mickyfin]

Great idea about this thread. Looks like your list is already starting to take shape

Our Syncro has been a labour of love too, and so looking fkrward t the new year, and good weather so I can sort out its bodywork.

[jed the spread]

The thing is PetenAli, your in a double dilemma. Once you have all the Syncro must have items you then have to satisfy your Westfalia must have items. I will read on with interest

jed

[KINGPRAWN]

Watching with interest Pete..... I'm nearly 10 yrs in now but my list changes daily!!!!!!!!

[KINGPRAWN]

Good luck with the blower fan.... Make sure you have a good few rolls of black tape, bucket of new crimp connectors and a huge box of patience ......NEVER want to do that again!! P.s the screws that hold most things on seem to be made of chocolate!

[syncropatrick]

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
rebuilt both gearboxes
replace all CVJs
replace various earth straps and clean crowns
replace ignition switch
wallet emptying bodywork
ongoing replacement of rubber bushes
underseal
replace both batteries
lift kit
SS exhaust

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!

[PetenAli]

The thing is PetenAli, your in a double dilemma. Once you have all the Syncro must have items you then have to satisfy your Westfalia must have items. I will read on with interest

jed

Thanks Jed. Because ours isn't a genuine Westfalia (its more of a "bitsa" to be honest) we aren't going to get too OTT about that side of things. Eventually we will go down the compressor fridge route but got other things to spend money on first. We are looking forward to seeing the promised feature on Campervan Culture on these fridges as well

[PetenAli]

Good luck with the blower fan.... Make sure you have a good few rolls of black tape, bucket of new crimp connectors and a huge box of patience ......NEVER want to do that again!! P.s the screws that hold most things on seem to be made of chocolate!

Hopefully this will be the first job on the list - getting done between Xmas and New Year. I've got a mate who is an electrical engineer and he's promised to help - result . If we can get that one out of the way I'll be a happy man. While the front is out we will try to tidy up the various additions to the wiring that have been made over the years. Some of them are labelled in French which gives away the van's Belgian origins.

[PetenAli]

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

Good luck Pete!

Thanks Patrick. We read your list with a bit of awe - its been worth it though as your van is going great on the evidence of the Picos trip. I guess there's just always stuff to do! What are your plans for your engine rebuild?

[jebiga41]

Must be on my umpteen list by now
From new
Engine change
Wheels and tyres
Bearings all round
Brakes all round
Front end rebuild and poly bushed
Wheel carriers on
Westy interior install
decent stereo
Leisure battery and split charge
Third brake light and additional reversing light
Oil cooler

After
New VC, awning, gearbox and diff rebuild, Engine change, Uprated clutch, Tank out,
Regrease cv joints all round ,Gear linkage overhaul, propex install, fit some worry clocks boost egt and oil pressure, compressor fridge, More insulation,Floor, Re trim interior, charge cooler install, New springs and front shocks, Upper Ball joint spacers, skid plate, fix gearbox and fit gearbox protection (hit it off a rock), stainless exhaust, new rad, fit window in bulkhead
After still
Gearbox and engine swap, fit different charge cooler (first one leaked) fit HD CV's, redo rear wheel bearings
(carriers had ovalled) rear disc conversion
Still to do
Paint back door (after 3 years ) fit new springs, seams, redo split charge system and finish off interior, do some body work (seams and a few dents), poptop the factory high top (watch this space ) install refillable LPG bottle, install 240 hook up. Fit different pump to engine and a few other bits.
Will be finished soon then only Tinkerbelle to worry about