Syncro Parts - general - Revision history

HarryMann: /* Fuel tank straps */

2012-12-25T01:36:11Z

Fuel tank straps

← Older revision		Revision as of 01:36, 25 December 2012
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	[[File:Syncro_tank_strap_ns_03.jpg]]		[[File:Syncro_tank_strap_ns_03.jpg]]

			'''NB.''' Size does matter in this case! So use the old parts to make the finished length correct.

	Tools:		Tools:

HarryMann: /* Fuel tank straps */

2012-12-25T01:33:54Z

Fuel tank straps

← Older revision		Revision as of 01:33, 25 December 2012
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	Spot-welds drilled out to ~~reveal a kit of~~ end bracket termination stiffeners~~, plus~~ one simple		Offside (Right-hand)
	strap and a complete ~~refurb~~ part ~~will~~ last another 20 years. ~~SImple spot welding is all that is required~~
			Spot-welds drilled out to re-use the end bracket termination stiffeners. Plus make one simple
			strap (2" x 1mm) and a complete refurbished part should last another 20 years.

			The ''kit'' of parts, old rusty main-strap used as a guide pattern only.

	[[File:Syncro_tank_strap_os_01.jpg]]		[[File:Syncro_tank_strap_os_01.jpg]]

HarryMann: /* Fuel tank straps */

2012-12-25T01:29:07Z

Fuel tank straps

← Older revision		Revision as of 01:29, 25 December 2012
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	And! Even more ways of ''~~repaiing~~'' tank straps...		And! Even more ways of ''repairng'' tank straps...

	by just replacing the really rotten parts and drilling out the spot-welds		by just replacing the really rotten parts and drilling out the spot-welds

HarryMann: /* Fuel tank straps */

2012-12-25T01:21:05Z

Fuel tank straps

← Older revision		Revision as of 01:21, 25 December 2012
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	----		----

	~~So,~~ more ways of repaiing tank straps...
			And! Even more ways of ''repaiing'' tank straps...

	by just replacing the really rotten parts and drilling out the spot-welds		by just replacing the really rotten parts and drilling out the spot-welds

HarryMann: /* Fuel tank straps */

2012-12-25T01:19:35Z

Fuel tank straps

← Older revision		Revision as of 01:19, 25 December 2012
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	----		----

	So, more ways of repaiing tank straps, by just replacing the really rotten parts and drilling the spot-welds		So, more ways of repaiing tank straps...
	to remove the doublers (thickeners) for anchoring brackets at each end (in pictures)
			by just replacing the really rotten parts and drilling out the spot-welds
			to remove the doublers (thickeners) for anchoring brackets at each end (in pictures)

	Nearside, extensively welded to fill-in perforations, and strengthen edges. NB. Slot cut to remove strap without		Nearside, extensively welded to fill-in perforations, and strengthen edges. NB. Slot cut to remove strap without

HarryMann: /* Fuel tank straps */

2012-12-25T01:18:31Z

Fuel tank straps

← Older revision		Revision as of 01:18, 25 December 2012
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	So, more ways of repaiing tank straps, by just replacing the really rotten parts and drilling the spot-welds		So, more ways of repaiing tank straps, by just replacing the really rotten parts and drilling the spot-welds
	to remove the doublers (thickeners) for anchoring brackets at each end (in pictures)		to remove the doublers (thickeners) for anchoring brackets at each end (in pictures)

			Nearside, extensively welded to fill-in perforations, and strengthen edges. NB. Slot cut to remove strap without

			disconnecting tank fuel supply hose, retained in repaired item, for easy refitting.

	[[File:Syncro_tank_strap_ns_01.jpg]]		[[File:Syncro_tank_strap_ns_01.jpg]]

	[[File:Syncro_tank_strap_ns_02.jpg]]		[[File:Syncro_tank_strap_ns_02.jpg]]
	~~[[File:Syncro_tank_strap_ns_03~~.~~jpg]]~~

			Spot-welds drilled out to reveal a kit of end bracket termination stiffeners, plus one simple
			strap and a complete refurb part will last another 20 years. SImple spot welding is all that is required

	[[File:Syncro_tank_strap_os_01.jpg]]		[[File:Syncro_tank_strap_os_01.jpg]]

	[[File:Syncro_tank_strap_os_02.jpg]]		[[File:Syncro_tank_strap_os_02.jpg]]

	[[File:Syncro_tank_strap_ns_03.jpg]]		[[File:Syncro_tank_strap_ns_03.jpg]]

			Tools:

			Spot-weld drill (cobalt)

			[[General QMAX hole punch\|QMAX hole punch]]

	== Handbrake cables ==		== Handbrake cables ==

HarryMann: /* Fuel tank straps */

2012-12-25T01:08:05Z

Fuel tank straps

← Older revision		Revision as of 01:08, 25 December 2012
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	[[Image:Syncro_tank_straps_01.jpg]]		[[Image:Syncro_tank_straps_01.jpg]]

	'''NB.''' If the tank straps are corroded badly, it's highly likely the fuel pump body may also be at the point it starts leaking due to corrosion, often bi-metallic corrosion due to starp bracket attachment contact (mine had a plastic filler repair, fuel poured out as I removed it from ~~barcket~~). Have found many others reporting same, here and in the US. Wrap new pump in plastic before fitting or use Duralac assembly compound (see General - Tips, Tricks & Techniques)		'''NB.''' If the tank straps are corroded badly, it's highly likely the fuel pump body may also be at the point it starts leaking due to corrosion, often bi-metallic corrosion due to starp bracket attachment contact (mine had a plastic filler repair, fuel poured out as I removed it from bracket). Have found many others reporting same, here and in the US. Wrap new pump in plastic before fitting or use Duralac assembly compound (see General - Tips, Tricks & Techniques)

	----		----

	De-rusting tank so-so straps [[Bodywork and Glass - Rust - Elecrolytic de-rusting]]		De-rusting tank so-so straps [[Bodywork and Glass - Rust - Elecrolytic de-rusting]]

			----

			So, more ways of repaiing tank straps, by just replacing the really rotten parts and drilling the spot-welds
			to remove the doublers (thickeners) for anchoring brackets at each end (in pictures)

			[[File:Syncro_tank_strap_ns_01.jpg]]
			[[File:Syncro_tank_strap_ns_02.jpg]]
			[[File:Syncro_tank_strap_ns_03.jpg]]

			[[File:Syncro_tank_strap_os_01.jpg]]
			[[File:Syncro_tank_strap_os_02.jpg]]
			[[File:Syncro_tank_strap_ns_03.jpg]]

	== Handbrake cables ==		== Handbrake cables ==

HarryMann at 22:56, 4 October 2010

2010-10-04T22:56:53Z

← Older revision		Revision as of 22:56, 4 October 2010
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	RHD syncro 2.1 DJ accelerator cable = 3700mm part number 252 721 555 R		RHD syncro 2.1 DJ accelerator cable = 3700mm part number 252 721 555 R


			==Drive shaft bolts==

			The front inner drive-shaft bolts are 50mm long, 2mm longer than the 2WD and the Syncro rears. The front driveshaft flanges have thick steel spacers between the flanges and the inner CV joints.

			The 6 bolts per joint use special serrated & hardened lock washers and go through 3 curved load spreader plates then into the joints. Torque is typically 30 ~ 32 ft-lb; the bolts can and do become loose if anything in the installation is imperfect. Use the higher torque figures preferably as well as ensuring all mating surfaces are clean before assembly.

			The bolts come in two flavours, hex socket cap-head and 12-point drive bolts - veeryone has their favourites, maybe more important is having them all the same and ensuring a suitable drive tool is in your tool-kit!

HarryMann: /* Captive nuts for front bash-plate */

2009-11-23T01:59:35Z

Captive nuts for front bash-plate

← Older revision		Revision as of 01:59, 23 November 2009
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	'''HarryMann:''' Indeed Simon! For the front bashplate, I just use M8 nuts and bolts about 20mm long, 3 per side if I can get them through the holes, else 2. Never had a problem, and quick enough to fit or remove... do not bother attaching front lip, but beat it out straight once per year!		'''HarryMann:''' Indeed Simon! For the front bashplate, I just use M8 nuts and bolts about 20mm long, 3 per side if I can get them through the holes, else 2. Never had a problem, and quick enough to fit or remove... do not bother attaching front lip, but beat it out straight once per year!

			I did find some captive nuts, almost identical to the original VW ones, they were Mercedes parts!

	==Accelerator cable ==		==Accelerator cable ==

	RHD syncro 2.1 DJ accelerator cable = 3700mm part number 252 721 555 R		RHD syncro 2.1 DJ accelerator cable = 3700mm part number 252 721 555 R

HarryMann: /* Fuel tank straps */

2009-11-23T01:58:19Z

Fuel tank straps

← Older revision		Revision as of 01:58, 23 November 2009
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	[http://www.kaefer-co.de/index.php?view=details&path=0.191.217.&size=large&id=2831 Syncro fuel-tank straps in Stainless available here]		[http://www.kaefer-co.de/index.php?view=details&path=0.191.217.&size=large&id=2831 Syncro fuel-tank straps in Stainless available here]

	'''NB.''' ''The following avoids having to remove the tank to repair the original (front) tank-strap anchor bolts. It worked fine, but is not a 'restoration' technique really, it's a 'get you out of trouble' method, until a proper restoration can be done.		'''NB.''' ''The following avoids having to remove the tank to repair the original (front) tank-strap anchor bolts. It worked fine, but is not a 'restoration' technique really, it's a 'get you out of trouble' method, until a proper restoration can be done.''
	''
	'''HarryMann:''' Having found that there wasn't much to attach any new straps to at the front of the tank (in fact couldn't even see up there how the originals had been attached), decided to use some thin stainless strip to make some up. To attach each one, to the back of the aft cross-member, I drilled two holes as high up as I could get with an extension drill bit, then bent up some clips from numpty metal rod. Hopefully the photos will explain...		'''HarryMann:''' Having found that there wasn't much to attach any new straps to at the front of the tank (in fact couldn't even see up there how the originals had been attached), decided to use some thin stainless strip to make some up. To attach each one, to the back of the aft cross-member, I drilled two holes as high up as I could get with an extension drill bit, then bent up some clips from numpty metal rod. Hopefully the photos will explain...